Inspection robot with removeable interface plates and method for configuring payload interfaces

ABSTRACT

Inspection robots with removeable interface plates and method for configuring payload interfaces are described. An example robot may include a payload, with at least one sensor, mounted to a housing of the inspection robot. The housing may include a removeable interface plate coupled to the at least one sensor and to an electronic board, the electronic board positioned within the housing. The removeable interface plate may define an electrical coupling interface compatible with the payload, and the electronic board may include an electrical processing configuration compatible with the payload.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to the following U.S. ProvisionalApplications: Ser. No. 63/177,141 (GROB-0010-P01) filed Apr. 20, 2021,and entitled “FLEXIBLE INSPECTION ROBOT FOR INDUSTRIAL ENVIRONMENTS”;and Ser. No. 63/255,880 (GROB-0010-P02) filed Oct. 14, 2021, andentitled “FLEXIBLE INSPECTION ROBOT.”

Each of the foregoing applications is incorporated herein by referencein its entirety.

This application also incorporates herein U.S. application Ser. No.16/863,594 (GROB-0007-U02) by reference in its entirety.

BACKGROUND

The present disclosure relates to robotic inspection and treatment ofindustrial surfaces.

SUMMARY

Previously known inspection and treatment systems for industrialsurfaces suffer from a number of drawbacks. Industrial surfaces areoften required to be inspected to determine whether a pipe wall, tanksurface, or other industrial surface feature has suffered fromcorrosion, degradation, loss of a coating, damage, wall thinning orwear, or other undesirable aspects. Industrial surfaces are oftenpresent within a hazardous location—for example in an environment withheavy operating equipment, operating at high temperatures, in a confinedenvironment, at a high elevation, in the presence of high voltageelectricity, in the presence of toxic or noxious gases, in the presenceof corrosive liquids, and/or in the presence of operating equipment thatis dangerous to personnel. Accordingly, presently known systems requirethat a system be shutdown, that a system be operated at a reducedcapacity, that stringent safety procedures be followed (e.g.,lockout/tagout, confined space entry procedures, harnessing, etc.),and/or that personnel are exposed to hazards even if proper proceduresare followed. Additionally, the inconvenience, hazards, and/or confinedspaces of personnel entry into inspection areas can result ininspections that are incomplete, of low resolution, that lack systematiccoverage of the inspected area, and/or that are prone to human error andjudgement in determining whether an area has been properly inspected.

Embodiments of the present disclosure provide for systems and methods ofinspecting an inspecting an inspection surface with an improvedinspection robot. Example embodiments include modular drive assembliesthat are selectively coupled to a chassis of the inspection robot,wherein each drive assembly may have distinct wheels suited to differenttypes of inspection surfaces. Other embodiments include payloadsselectively couplable to the inspection robot chassis via universalconnectors that provide for the exchange of couplant, electrical powerand/or data communications. The payload may each have different sensorconfigurations suited for interrogating different types of inspectionsurfaces.

Embodiments of the present disclosure may provide for improved customerresponsiveness by generating interactive inspection maps that depictpast, present and/or predicted inspection data of an inspection surface.In embodiments, the inspection maps may be transmitted and displayed onuser electronic devices and may provide for control of the inspectionrobot during an inspection run.

Embodiments of the present disclosure may provide for an inspectionrobot with improved environmental capabilities. For example, someembodiments have features for operating in hostile environments, e.g.,high temperature environments. Such embodiments may include lowoperational impact capable cooling systems.

Embodiments of the present disclosure may provide for an inspectionrobot having an improved, e.g., reduced, footprint which may furtherprovide for increased climbing of inclined and/or vertical inspectionsurfaces. The reduced footprint of certain embodiments may also providefor inspection robots having improve the horizontal range due to reducedweight.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a schematic depiction of an inspection robot consistent withcertain embodiments of the present disclosure.

FIG. 2 is a schematic depiction of a payload consistent with certainembodiments of the present disclosure.

FIG. 3 is a schematic depiction of an inspection surface.

FIG. 4 is a schematic depiction of an inspection robot positioned on aninspection surface.

FIG. 5 is a schematic depiction of a location on an inspection surface.

FIG. 6 is a schematic block diagram of an apparatus for providing aninspection map.

FIG. 7 depicts an illustrative inspection map.

FIG. 8 depicts an illustrative inspection map and focus data.

FIGS. 9-10 are schematic depictions of wheels for an inspection robot.

FIG. 11 is a schematic diagram of a payload arrangement.

FIG. 12 is another schematic diagram of a payload arrangement.

FIG. 13 is another schematic diagram of a payload arrangement.

FIG. 14 is a schematic block diagram of an apparatus for providingposition informed inspection data.

FIG. 15 is a schematic flow diagram of a procedure to provide positioninformed inspection data.

FIG. 16 is a schematic flow diagram of another procedure to provideposition informed inspection data.

FIG. 17 depicts a schematic of an example system including a basestation and an inspection robot.

FIG. 18 depicts an internal view of certain components of the centermodule.

FIG. 19 depicts an exploded view of a cold plate on the bottom surfaceof the center module.

FIG. 20 depicts an example bottom surface of the center module.

FIGS. 21-22 depict an exterior view of a drive module, having an encoderin a first position and in a second position.

FIG. 23 depicts an exploded view of a drive module.

FIG. 24 depicts an exploded view of a drive wheel actuator.

FIG. 25 depicts an exploded view of a first embodiment of a stabilitymodule and drive module.

FIGS. 26-27 depict two side views of the first embodiment of thestability module.

FIG. 28 depicts an alternate embodiment of a stability module and wheelassembly.

FIG. 29 depicts a cross section view of drive module coupling to acenter module.

FIGS. 30-31 depicts two side views of a drive module rotated relative tothe center module.

FIG. 32 depicts an exploded view of a dovetail payload rail mountassembly.

FIG. 33 depicts a payload with sensor carriages and an inspectioncamera.

FIG. 34 depicts an example side view of a payload and inspection camera.

FIGS. 35-36 depict details of an example inspection camera.

FIGS. 37-38 depict clamped and un-clamped views of a sensor clamp.

FIG. 39 depicts an exploded view of a sensor carriage clamp.

FIG. 40 depicts a sensor carriage having a multi-sensor sled assembly.

FIGS. 41-42 depict views of two different sized multi-sensor sledassemblies.

FIG. 43 depicts a front view of a multi-sensor sled assembly.

FIG. 44 depicts a sensor carriage with a universal single-sensor sledassembly.

FIG. 45 depicts an embodiment of an inspection robot with a tether.

FIG. 46 depicts an example stability module assembly.

FIG. 47 is a schematic diagram of a system for traversing an obstaclewith an inspection robot.

FIG. 48 is a flow chart depicting a method for traversing an obstaclewith an inspection robot.

FIG. 49 depicts a payload for an inspection robot.

FIG. 50 depicts an example payload having an arm and two sleds mountedthereto.

FIG. 51 depicts an example payload having two arms and four sledsmounted thereto.

FIG. 52 depicts a top view of the example payload of FIG. 52.

FIG. 53 depicts a bottom view of two sleds in a pivoted position.

FIG. 54 depicts a system capable to perform rapid configuration of aninspection robot.

FIGS. 55-56 depict systems for providing real-time processed inspectiondata to a user.

FIG. 57 depicts an example inspection robot.

FIG. 58 is a perspective view of a corner of an example inspectionrobot.

FIGS. 59-61 depict various drive module configurations.

FIGS. 62-63 depict examples of a center encoder.

FIG. 64 depicts an example wheel and drive module.

FIGS. 65-66 depicts example rail components.

FIG. 67-68 depict example rail configurations.

FIG. 69 depicts an example removeable interface plate.

FIGS. 70A-70B depict example gaskets for a removeable interface plate.

FIG. 71 depicts an example removeable interface plate.

FIG. 72 depicts an example interior of a housing.

FIGS. 73-74 depict the top and bottom of a housing.

FIG. 75 depicts a rear view of an example inspection robot.

FIG. 76 is a schematic flow depiction of an example coolant flow path.

FIG. 77 is a schematic of an example inspection robot.

FIG. 78 is a side view of an example inspection robot.

FIG. 79 is a front view of an example inspection robot.

FIG. 80 depicts a drive module linkage.

FIG. 81 depicts an example inspection robot.

FIG. 82 depicts a schematic example electronic board.

FIG. 83 depicts example electronic board

FIG. 84 depicts a schematic of an inspection robot.

FIG. 85 depicts a schematic of an inspection robot.

FIG. 86 depicts a controller schematic.

FIG. 87 depicts a schematic of a procedure for rapid configuration of aninspection robot.

FIG. 88 depicts a schematic of a procedure for confirming operationsassociated with inspection operations.

FIG. 89 depicts a schematic of a procedure for confirming operationsassociated with inspection operations.

FIG. 90 depicts a schematic of an inspection robot.

FIG. 91 depicts an example bottom view of an inspection robot with aportion of the couplant retaining chamber formed by the housing.

FIG. 92 depicts a schematic of an inspection robot in a side view.

FIG. 93 depicts a schematic of a drive module is formed from a wheelsection and a drive motor section.

FIG. 94 depicts a schematic of an example inspection robot illustratingan internal couplant retaining chamber and certain control features forthe couplant flow path.

FIG. 95 depicts a schematic an example inspection robot configured in asimilar arrangement to the example of FIG. 94.

FIG. 96 depicts a schematic an example inspection robot illustratingexample heat generating components that may be present in certainembodiments.

FIG. 97 depicts a schematic of an example procedure for cooling one ormore components of an inspection robot.

FIG. 98 depicts a schematic of an example procedure which may beutilized in conjunction with and/or as a part of procedure for coolingone or more components of an inspection robot.

FIG. 99 depicts a schematic of an example apparatus for performingthermal management of an inspection robot and/or components of aninspection robot.

FIG. 100 depicts a schematic of an example procedure for performingthermal management of an inspection robot and/or components of aninspection robot.

FIG. 101 depicts a schematic of an example controller for flexibleconfiguration and/or operation of a drive module.

FIG. 102 depicts a schematic of an example procedure for configuring aninspection robot and/or swapping drive modules of an inspection robot.

FIG. 103 depicts a schematic of an example procedure.

FIG. 104 depicts a schematic of an example procedure to swap a drivemodule and/or a payload of an inspection robot.

FIG. 105 depicts a schematic of an example procedure to configure aninspection robot utilizing a second payload.

FIG. 106 depicts a schematic of an example procedure including anoperation to request a configuration update in response to the payloadidentification value.

FIG. 107 depicts a schematic of an example procedure including anoperation to provide an incompatibility notification.

FIG. 108 represents an embodiment of an inspection robot.

FIG. 109 represents an embodiment of an inspection robot.

FIG. 110 depicts a schematic of an inspection robot with an encoder.

FIG. 111 depicts a schematic of an inspection robot.

FIG. 112 depicts multiple rail components.

FIG. 113 depicts a method of provisioning an inspection robot.

FIG. 114 depicts an inspection robot.

FIG. 115 depicts an inspection robot.

FIGS. 116-124 are flowcharts illustrating example processes forassembling an inspection robot.

FIG. 125 is a block diagram illustrating an example inspection system onan inspection surface.

FIG. 126 is a flowchart illustrating an example process for inspectingan inspection surface.

FIG. 127 is a flowchart illustrating an example process forreconfiguring an inspection robot wheel in response to an inspectionenvironment.

FIG. 128A is a top view of an example inspection robot including anindependent drive module suspension system.

FIG. 128B is a side view of the example inspection robot of FIG. 128A.

FIGS. 129-130 are box diagrams of example inspection robots.

FIG. 131 depicts a schematic of a tether.

DETAILED DESCRIPTION

The present disclosure relates to a system developed for traversing,climbing, or otherwise traveling over walls (curved or flat), or otherindustrial surfaces. Industrial surfaces, as described herein, includeany tank, pipe, housing, or other surface utilized in an industrialenvironment, including at least heating and cooling pipes, conveyancepipes or conduits, and tanks, reactors, mixers, or containers. Incertain embodiments, an industrial surface is ferromagnetic, for exampleincluding iron, steel, nickel, cobalt, and alloys thereof. In certainembodiments, an industrial surface is not ferromagnetic.

Certain descriptions herein include operations to inspect a surface, aninspection robot or inspection device, or other descriptions in thecontext of performing an inspection. Inspections, as utilized herein,should be understood broadly. Without limiting any other disclosures orembodiments herein, inspection operations herein include operating oneor more sensors in relation to an inspected surface, electromagneticradiation inspection of a surface (e.g., operating a camera) whether inthe visible spectrum or otherwise (e.g., infrared, UV, X-Ray, gamma ray,etc.), high-resolution inspection of the surface itself (e.g., a laserprofiler, caliper, etc.), performing a repair operation on a surface,performing a cleaning operation on a surface, and/or marking a surfacefor a later operation (e.g., for further inspection, for repair, and/orfor later analysis). Inspection operations include operations for apayload carrying a sensor or an array of sensors (e.g. on sensor sleds)for measuring characteristics of a surface being traversed such asthickness of the surface, curvature of the surface, ultrasound (orultra-sonic) measurements to test the integrity of the surface and/orthe thickness of the material forming the surface, heat transfer, heatprofile/mapping, profiles or mapping any other parameters, the presenceof rust or other corrosion, surface defects or pitting, the presence oforganic matter or mineral deposits on the surface, weld quality and thelike. Sensors may include magnetic induction sensors, acoustic sensors,laser sensors, LIDAR, a variety of image sensors, and the like. Theinspection sled may carry a sensor for measuring characteristics nearthe surface being traversed, such as emission sensors to test for gasleaks, air quality monitoring, radioactivity, the presence of liquids,electro-magnetic interference, visual data of the surface beingtraversed such as uniformity, reflectance, status of coatings such asepoxy coatings, wall thickness values or patterns, wear patterns, andthe like. The term inspection sled may indicate one or more tools forrepairing, welding, cleaning, applying a treatment or coating thesurface being treated. Treatments and coatings may include rustproofing, sealing, painting, application of a coating, and the like.Cleaning and repairing may include removing debris, sealing leaks,patching cracks, and the like. The term inspection sled, sensor sled,and sled may be used interchangeably throughout the present disclosure.

In certain embodiments, for clarity of description, a sensor isdescribed in certain contexts throughout the present disclosure, but itis understood explicitly that one or more tools for repairing, cleaning,and/or applying a treatment or coating to the surface being treated arelikewise contemplated herein wherever a sensor is referenced. In certainembodiments, where a sensor provides a detected value (e.g., inspectiondata or the like), a sensor rather than a tool may be contemplated,and/or a tool providing a feedback value (e.g., application pressure,application amount, nozzle open time, orientation, etc.) may becontemplated as a sensor in such contexts.

Inspections are conducted with a robotic system 100 (e.g., an inspectionrobot, a robotic vehicle, etc.) which may utilize sensor sleds 1 and asled array system 2 which enables accurate, self-aligning, andself-stabilizing contact with a surface (not shown) while alsoovercoming physical obstacles and maneuvering at varying or constantspeeds. In certain embodiments, mobile contact of the system 100 withthe surface includes a magnetic wheel 3. In certain embodiments, a sledarray system 2 is referenced herein as a payload 2—wherein a payload 2is an arrangement of sleds 1 with sensor mounted thereon, and wherein,in certain embodiments, an entire payload 2 can be changed out as aunit. The utilization of payloads 2, in certain embodiments, allows fora pre-configured sensor array that provides for rapid re-configurationby swapping out the entire payload 2. In certain embodiments, sleds 1and/or specific sensors on sleds 1, are changeable within a payload 2 toreconfigure the sensor array.

An example sensor sled 1 includes, without limitation, one or moresensors mounted thereon such that the sensor(s) is operationallycouplable to an inspection surface in contact with a bottom surface ofthe corresponding one of the sleds. For example, the sled 1 may includea chamber or mounting structure, with a hole at the bottom of the sled 1such that the sensor can maintain line-of-sight and/or acoustic couplingwith the inspection surface. The sled 1 as described throughout thepresent disclosure is mounted on and/or operationally coupled to theinspection robot 100 such that the sensor maintains a specifiedalignment to the inspection surface 500—for example a perpendiculararrangement to the inspection surface, or any other specified angle. Incertain embodiments, a sensor mounted on a sled 1 may have aline-of-sight or other detecting arrangement to the inspection surfacethat is not through the sled 1—for example a sensor may be mounted at afront or rear of a sled 1, mounted on top of a sled 1 (e.g., having aview of the inspection surface that is forward, behind, to a side,and/or oblique to the sled 1). It will be seen that, regardless of thesensing orientation of the sensor to the inspection surface, maintenanceof the sled 1 orientation to the inspection surface will support moreconsistent detection of the inspection surface by the sensor, and/orsensed values (e.g., inspection data) that is more consistentlycomparable over the inspection surface and/or that has a meaningfulposition relationship compared to position information determined forthe sled 1 or inspection robot 100. In certain embodiments, a sensor maybe mounted on the inspection robot 100 and/or a payload 2—for example acamera mounted on the inspection robot 100.

The present disclosure allows for gathering of structural informationfrom a physical structure. Example physical structures includeindustrial structures such as boilers, pipelines, tanks, ferromagneticstructures, and other structures. An example system 100 is configuredfor climbing the outside of tube walls.

As described in greater detail below, in certain embodiments, thedisclosure provides a system that is capable of integrating input fromsensors and sensing technology that may be placed on a robotic vehicle.The robotic vehicle is capable of multi-directional movement on avariety of surfaces, including flat walls, curved surfaces, ceilings,and/or floors (e.g., a tank bottom, a storage tank floor, and/or arecovery boiler floor). The ability of the robotic vehicle to operate inthis way provides unique access especially to traditionally inaccessibleor dangerous places, thus permitting the robotic vehicle to gatherinformation about the structure it is climbing on.

The system 100 (e.g., an inspection robot, a robotic vehicle, and/orsupporting devices such as external computing devices, couplant or fluidreservoirs and delivery systems, etc.) in FIG. 1 includes the sled 1mounted on a payload 2 to provide for an array of sensors havingselectable contact (e.g., orientation, down force, sensor spacing fromthe surface, etc.) with an inspected surface. The payload 2 includesmounting posts mounted to a housing (main body) 102 of the system 100.The payload 2 thereby provides a convenient mounting position for anumber of sleds 1, allowing for multiple sensors to be positioned forinspection in a single traverse of the inspected surface. The number anddistance of the sleds 1 on the payload 2 are readily adjustable—forexample by sliding the sled mounts on the payload 2 to adjust spacing.

Referencing FIG. 2, an example system 100 includes the sled 1 held by anarm 20 that is connected to the payload 2 (e.g., a sensor array orsensor suite). An example system includes the sled 1 coupled to the arm20 at a pivot point 17, allowing the sensor sled to rotate and/or tilt.On top of the arm 20, an example payload 2 includes a biasing member 21(e.g., a torsion spring) with another pivot point 16, which provides fora selectable down-force of the arm 20 to the surface being inspected,and for an additional degree of freedom in sled 1 movement to ensure thesled 1 orients in a desired manner to the surface. In certainembodiments, down-force provides for at least a partial seal between thesensor sled 1 and surface to reduce or control couplant loss (e.g.,where couplant loss is an amount of couplant consumed that is beyondwhat is required for operations), control distance between the sensorand the surface, and/or to ensure orientation of the sensor relative tothe surface. Additionally or alternatively, the arm 20 can lift in thepresence of an obstacle, while traversing between surfaces, or the like,and return to the desired position after the maneuver is completed. Incertain embodiments, an additional pivot 18 couples the arm 20 to thepayload 2, allowing for an additional rolling motion. In certainembodiments, pivots 16, 17, 18 provide for three degrees of freedom onarm 20 motion, allowing the arm 20 to be responsive to almost anyobstacle or surface shape for inspection operations. In certainembodiments, various features of the system 100, including one or morepivots 16, 17, 18, co-operate to provide self-alignment of the sled 1(and thus, the sensor mounted on the sled) to the surface. In certainembodiments, the sled 1 self-aligns to a curved surface and/or to asurface having variability in the surface shape.

In certain embodiments, the system is also able to collect informationat multiple locations at once. This may be accomplished through the useof a sled array system. Modular in design, the sled array system allowsfor mounting sensor mounts, like the sleds, in fixed positions to ensurethorough coverage over varying contours. Furthermore, the sled arraysystem allows for adjustment in spacing between sensors, adjustments ofsled angle, and traveling over obstacles. In certain embodiments, thesled array system was designed to allow for multiplicity, allowingsensors to be added to or removed from the design, including changes inthe type, quantity, and/or physical sensing arrangement of sensors. Thesensor sleds that may be employed within the context of the presentinvention may house different sensors for diverse modalities useful forinspection of a structure. These sensor sleds are able to stabilize,align, travel over obstacles, and control, reduce, or optimize couplantdelivery which allows for improved sensor feedback, reduced couplantloss, reduced post-inspection clean-up, reduced down-time due to sensorre-runs or bad data, and/or faster return to service for inspectedequipment.

There may be advantages to maintaining a sled with associated sensors ortools in contact and/or in a fixed orientation relative to the surfacebeing traversed even when that surface is contoured, includes physicalfeatures, obstacles, and the like. In embodiments, there may be sledassemblies which are self-aligning to accommodate variabilities in thesurface being traversed (e.g., an inspection surface) while maintainingthe bottom surface of the sled (and/or a sensor or tool, e.g. where thesensor or tool protrudes through or is flush with a bottom surface ofthe sled) in contact with the inspection surface and the sensor or toolin a fixed orientation relative to the inspection surface. In anembodiment, as shown in FIG. 13 there may be a number of payloads 2,each payload 2 including a sled 1 positioned between a pair of sled arms20, with each side exterior of the sled 1 attached to one end of each ofthe sled arms 20 at a pivot point 17 so that the sled 1 is able torotate around an axis that would run between the pivot points 17 on eachside of the sled 1. As described elsewhere herein, the payload 2 mayinclude one or more inspection sleds 1 being pushed ahead of the payload2, pulled behind the payload 2, or both. The other end of each sled arm20 is attached to an inspection sled mount 14 with a pivot connection 16which allows the sled arms to rotate around an axis running through theinspection sled mount 14 between the two pivot connections 16.Accordingly, each pair of sled arms 20 can raise or lower independentlyfrom other sled arms 20, and with the corresponding sled 1. Theinspection sled mount 14 attaches to the payload 2, for example bymounting on shaft 19. The inspection sled mount 14 may connect to thepayload shaft 19 with a connection 18 which allows the sled 1 andcorresponding arms 20 to rotate from side to side in an arc around aperpendicular to the shaft 19. Together the up and down and side to sidearc, where present, allow two degrees of rotational freedom to the sledarms. Connection 18 is illustrated as a gimbal mount in the example ofFIG. 4, although any type of connection providing a rotational degree offreedom for movement is contemplated herein, as well as embodiments thatdo not include a rotational degree of freedom for movement. The gimbalmount 18 allows the sled 1 and associated arms 20 to rotate toaccommodate side to side variability in the surface being traversed orobstacles on one side of the sled 1. The pivot points 17 between thesled arms 20 and the sled 1 allow the sled 1 to rotate (e.g., tilt inthe direction of movement of the inspection robot 100) to conform to thesurface being traversed and accommodate to variations or obstacles inthe surface being traversed. Pivot point 17, together with therotational freedom of the arms, provides the sled three degrees ofrotational freedom relative to the inspection surface. The ability toconform to the surface being traversed facilitated the maintenance of aperpendicular interface between the sensor and the surface allowing forimproved interaction between the sled 1 and the inspection surface.Improved interaction may include ensuring that the sensor isoperationally couplable to the inspection surface.

Within the inspection sled mount 14 there may be a biasing member (e.g.,torsion spring 21) which provides a down force to the sled 1 andcorresponding arms 20. In the example, the down force is selectable bychanging the torsion spring, and/or by adjusting the configuration ofthe torsion spring (e.g., confining or rotating the torsion spring toincrease or decrease the down force). Analogous operations or structuresto adjust the down force for other biasing members (e.g., a cylindricalspring, actuator for active down force control, etc.) are contemplatedherein.

In certain embodiments, the inspection robot 100 includes a tether (notshown) to provide power, couplant or other fluids, and/or communicationlinks to the robot 100. It has been demonstrated that a tether tosupport at least 200 vertical feet of climbing can be created, capableof couplant delivery to multiple ultra-sonic sensors, sufficient powerfor the robot, and sufficient communication for real-time processing ata computing device remote from the robot. Certain aspects of thedisclosure herein, such as but not limited to utilizing couplantconservation features such as sled downforce configurations, theacoustic cone, and water as a couplant, support an extended length oftether. In certain embodiments, multiple ultra-sonic sensors can beprovided with sufficient couplant through a ⅛″ couplant delivery line,and/or through a ¼″ couplant delivery line to the inspection robot 100,with ⅛″ final delivery lines to individual sensors. While the inspectionrobot 100 is described as receiving power, couplant, and communicationsthrough a tether, any or all of these, or other aspects utilized by theinspection robot 100 (e.g., paint, marking fluid, cleaning fluid, repairsolutions, etc.) may be provided through a tether or provided in situ onthe inspection robot 100. For example, the inspection robot 100 mayutilize batteries, a fuel cell, and/or capacitors to provide power; acouplant reservoir and/or other fluid reservoir on the robot to providefluids utilized during inspection operations, and/or wirelesscommunication of any type for communications, and/or store data in amemory location on the robot for utilization after an inspectionoperation or a portion of an inspection operation.

In certain embodiments, maintaining sleds 1 (and sensors or toolsmounted thereupon) in contact and/or selectively oriented (e.g.,perpendicular) to a surface being traversed provides for: reduced noise,reduced lost-data periods, fewer false positives, and/or improvedquality of sensing; and/or improved efficacy of tools associated withthe sled (less time to complete a repair, cleaning, or markingoperation; lower utilization of associated fluids therewith; improvedconfidence of a successful repair, cleaning, or marking operation,etc.). In certain embodiments, maintaining sleds 1 in contacts and/orselectively oriented to the surface being traversed provides for reducedlosses of couplant during inspection operations.

In certain embodiments, the combination of the pivot points 16, 17, 18)and torsion spring 21 act together to position the sled 1 perpendicularto the surface being traversed. The biasing force of the spring 21 mayact to extend the sled arms 20 downward and away from the payload shaft19 and inspection sled mount 14, pushing the sled 1 toward theinspection surface. The torsion spring 21 may be passive, applying aconstant downward pressure, or the torsion spring 21 or other biasingmember may be active, allowing the downward pressure to be varied. In anillustrative and non-limiting example, an active torsion spring 21 mightbe responsive to a command to relax the spring tension, reducingdownward pressure and/or to actively pull the sled 1 up, when the sled 1encounters an obstacle, allowing the sled 1 to more easily move over theobstacle. The active torsion spring 21 may then be responsive to acommand to restore tension, increasing downward pressure once theobstacle is cleared to maintain the close contact between the sled 1 andthe surface. The use of an active spring may enable changing the angleof a sensor or tool relative to the surface being traversed during atraverse. Design considerations with respect to the surfaces beinginspected may be used to design the active control system. If the spring21 is designed to fail closed, the result would be similar to a passivespring and the sled 1 would be pushed toward the surface beinginspected. If the spring 21 is designed to fail open, the result wouldbe increased obstacle clearance capabilities. In embodiments, spring 21may be a combination of passive and active biasing members.

The downward pressure applied by the torsion spring 21 may besupplemented by a spring within the sled 1 further pushing a sensor ortool toward the surface. The downward pressure may be supplemented byone or more magnets in/on the sled 1 pulling the sled 1 toward thesurface being traversed. The one or more magnets may be passive magnetsthat are constantly pulling the sled 1 toward the surface beingtraversed, facilitating a constant distance between the sled 1 and thesurface. The one or magnets may be active magnets where the magnet fieldstrength is controlled based on sensed orientation and/or distance ofthe sled 1 relative to the inspection surface. In an illustrative andnon-limiting example, as the sled 1 lifts up from the surface to clearan obstacle and it starts to roll, the strength of the magnet may beincreased to correct the orientation of the sled 1 and draw it backtoward the surface.

The connection between each sled 1 and the sled arms 20 may constitute asimple pin or other quick release connect/disconnect attachment. Thequick release connection at the pivot points 17 may facilitate attachingand detaching sleds 1 enabling a user to easily change the type ofinspection sled attached, swapping sensors, types of sensors, tools, andthe like.

In embodiments, as depicted in FIG. 16, there may be multiple attachmentor pivot point accommodations 9 available on the sled 1 for connectingthe sled arms 20. The location of the pivot point accommodations 9 onthe sled 1 may be selected to accommodate conflicting goals such as sled1 stability and clearance of surface obstacles. Positioning the pivotpoint accommodations 9 behind the center of sled in the longitudinaldirection of travel may facilitate clearing obstacles on the surfacebeing traversed. Positioning the pivot point accommodation 9 forward ofthe center may make it more difficult for the sled 1 to invert or flipto a position where it cannot return to a proper inspection operationposition. It may be desirable to alter the connection location of thesled arms 20 to the pivot point accommodations 9 (thereby defining thepivot point 17) depending on the direction of travel. The location ofthe pivot points 17 on the sled 1 may be selected to accommodateconflicting goals such as sensor positioning relative to the surface andavoiding excessive wear on the bottom of the sled. In certainembodiments, where multiple pivot point accommodations 9 are available,pivot point 17 selection can occur before an inspection operation,and/or be selectable during an inspection operation (e.g., arms 20having an actuator to engage a selected one of the pivot points 9, suchas extending pegs or other actuated elements, thereby selecting thepivot point 17).

In embodiments, the degree of rotation allowed by the pivot points 17may be adjustable. This may be done using mechanical means such as aphysical pin or lock. In embodiments, the connection between the sled 1and the sled arms 20 may include a spring that biases the pivot points17 to tend to pivot in one direction or another. The spring may bepassive, with the selection of the spring based on the desired strengthof the bias, and the installation of the spring may be such as topreferentially push the front or the back of the sled 1 down. Inembodiments, the spring may be active, and the strength and preferentialpivot may be varied based on direction of travel, presence of obstacles,desired pivoting responsiveness of the sled 1 to the presence of anobstacle or variation in the inspection surface, and the like. Incertain embodiments, opposing springs or biasing members may be utilizedto bias the sled 1 back to a selected position (e.g., neutral/flat onthe surface, tilted forward, tilted rearward, etc.). Where the sled 1 isbiased in a given direction (e.g., forward or rearward), the sled 1 maynevertheless operate in a neutral position during inspection operations,for example due to the down force from the arm 20 on the sled 1.

For a surface having a variable curvature, a chamfer or curve on thebottom surface of a sled 1 tends to guide the sled 1 to a portion of thevariable curvature matching the curvature of the bottom surface.Accordingly, the curved bottom surface supports maintaining a selectedorientation of the sled 1 to the inspection surface. In certainembodiments, the bottom surface of the sled 1 is not curved, and one ormore pivots 16, 17, 18 combined with the down force from the arms 20combine to support maintaining a selected orientation of the sled 1 tothe inspection surface. In some embodiments, the bottom of the sled 1may be flexible such that the curvature may adapt to the curvature ofthe surface being traversed.

The material on the bottom of the sled 1 may be chosen to prevent wearon the sled 1, reduce friction between the sled 1 and the surface beingtraversed, or a combination of both. Materials for the bottom of thesled may include materials such as plastic, metal, or a combinationthereof. Materials for the bottom of the sled may include an epoxy coat,a replaceable layer of polytetrafluoroethylene (e.g., Teflon), acetyl(e.g.,—Delrin® acetyl resin), ultrafine molecular weight polyethylene(PMW), and the like.

Certain embodiments include an apparatus for providing acoustic couplingbetween a carriage (or sled) mounted sensor and an inspection surface.Example and non-limiting structures to provide acoustic coupling betweena carriage mounted sensor and an inspection surface include an acoustic(e.g., an ultra-sonic) sensor mounted on a sled 1, the sled 1 mounted ona payload 2, and the payload 2 coupled to an inspection robot. Anexample apparatus further includes providing the sled 1 with a number ofdegrees of freedom of motion, such that the sled 1 can maintain aselected orientation with the inspection surface—including aperpendicular orientation and/or a selected angle of orientation.Additionally or alternatively, the sled 1 is configured to track thesurface, for example utilizing a shaped bottom of the sled 1 to match ashape of the inspection surface or a portion of the inspection surface,and/or the sled 1 having an orientation such that, when the bottomsurface of the sled 1 is positioned against the inspection surface, thesensor maintains a selected angle with respect to the inspectionsurface.

Certain additional embodiments of an apparatus for providing acousticcoupling between a carriage mounted sensor and an inspection surfaceinclude utilization of a fixed-distance structure that ensures aconsistent distance between the sensor and the inspection surface. Forexample, the sensor may be mounted on a cone, wherein an end of the conetouches the inspection surface and/or is maintained in a fixed positionrelative to the inspection surface, and the sensor mounted on the conethereby is provided at a fixed distance from the inspection surface. Incertain embodiments, the sensor may be mounted on the cone, and the conemounted on the sled 1, such that a change-out of the sled 1 can beperformed to change out the sensor, without engaging or disengaging thesensor from the cone. In certain embodiments, the cone may be configuredsuch that couplant provided to the cone results in a filled couplantchamber between a transducer of the sensor and the inspection surface.In certain additional embodiments, a couplant entry position for thecone is provided at a vertically upper position of the cone, between thecone tip portion and the sensor mounting end, in an orientation of theinspection robot as it is positioned on the surface, such that couplantflow through the cone tends to prevent bubble formation in the acousticpath between the sensor and the inspection surface. In certain furtherembodiments, the couplant flow to the cone is adjustable, and iscapable, for example, to be increased in response to a determinationthat a bubble may have formed within the cone and/or within the acousticpath between the sensor and the inspection surface. In certainembodiments, the sled 1 is capable of being lifted, for example with anactuator that lifts an arm 20, and/or that lifts a payload 2, such thata free fluid path for couplant and attendant bubbles to exit the coneand/or the acoustic path is provided. In certain embodiments, operationsto eliminate bubbles in the cone and/or acoustic path are performedperiodically, episodically (e.g., after a given inspection distance iscompleted, at the beginning of an inspection run, after an inspectionrobot pauses for any reason, etc.), and/or in response to an activedetermination that a bubble may be present in the cone and/or theacoustic path.

An example apparatus provides for low or reduced fluid loss of couplantduring inspection operations. Example and non-limiting structures toprovide for low or reduced fluid loss include providing for a limitedflow path of couplant out of the inspection robot system—for exampleutilizing a cone having a smaller exit couplant cross-sectional areathan a cross-sectional area of a couplant chamber within the cone. Incertain embodiments, an apparatus for low or reduced fluid loss ofcouplant includes structures to provide for a selected down force on asled 1 which the sensor is mounted on, on an arm 20 carrying a sled 1which the sensor is mounted on, and/or on a payload 2 which the sled 1is mounted on. Additionally or alternatively, an apparatus providing forlow or reduced fluid loss of couplant includes a selected down force ona cone providing for couplant connectivity between the sensor and theinspection surface—for example a leaf spring or other biasing memberwithin the sled 1 providing for a selected down force directly to thecone. In certain embodiments, low or reduced fluid loss includesproviding for an overall fluid flow of between 0.12 to 0.16 gallons perminute to the inspection robot to support at least 10 ultra-sonicsensors. In certain embodiments, low or reduced fluid loss includesproviding for an overall fluid flow of less than 50 feet per minute,less than 100 feet per minute, and less than 200 feet per minute fluidvelocity in a tubing line feeding couplant to the inspection robot. Incertain embodiments, low or reduced fluid loss includes providingsufficient couplant through a ¼″ tubing line to feed couplant to atleast 6, at least 8, at least 10, at least 12, or at least 16ultra-sonic sensors to a vertical height of at least 25 feet, at least50 feet, at least 100 feet, at least 150 feet, or at least 200 feet. Anexample apparatus includes a ¼″ feed line to the inspection robot and/orto the payload 2, and a ⅛″ feed line to individual sleds 1 and/orsensors (or acoustic cones associated with the sensors). In certainembodiments, larger and/or smaller diameter feed and individual fluidlines are provided.

The wheel 200 includes a channel 7 formed between enclosures 3, forexample at the center of the wheel 200. In certain embodiments, thechannel 7 provides for self-alignment on surfaces such as tubes orpipes. In certain embodiments, the enclosures 3 include one or morechamfered edges or surfaces, for example to improve contact with a roughor curved surface, and/or to provide for a selected surface contact areato avoid damage to the surface and/or the wheel 200. The flat face alongthe rim also allows for adhesion and predictable movement on flatsurfaces.

The wheel 200 may be connected to the shaft using a splined hub 8. Thisdesign makes the wheel modular and also prevents it from binding due tocorrosion. The splined hub 8 transfers the driving force from the shaftto the wheel. An example wheel 200 includes a magnetic aspect (e.g.,magnet 6) capable to hold the robot on the wall, and accept a drivingforce to propel the robot, the magnet 6 positioned between conductiveand/or ferromagnetic plates or enclosures, a channel 7 formed by theenclosures or plates, one or more chamfered and/or shaped edges, and/ora splined hub attachment to a shaft upon which the wheel is mounted.

The robotic vehicle may utilize a magnet-based wheel design that enablesthe vehicle to attach itself to and operate on ferromagnetic surfaces,including vertical and inverted surfaces (e.g., walls and ceilings).

The wheel 200 may have guiding features 2052 (reference FIGS. 9 to 10),such as grooves, concave or convex curvature, chamfers on the innerand/or outer edges, and the like. Referencing FIG. 9, an example guidingfeature 2052 includes a chamfer on an outer edge of one or bothenclosures 3, for example providing self-alignment of the wheels along asurface feature, such as between raised features, on top of raisedfeatures, between two pipes 502 (which may be adjacent pipes or spacedpipes), and/or a curvature of a tube, pipe, or tank (e.g., when theinspection robot 100 traverses the interior of a pipe 502). Forinstance, having a chamfer on the outer edge of the outside enclosuremay enable the wheel to more easily seat next to, and track along a pipe502 that is located outside the wheel. In another instance, havingchamfers on both edges may enable the wheel to track with greaterstability between two pipes 502. Referencing FIG. 10, guiding features2052 are depicted as chamfers on both sides of the wheel enclosures3—for example allowing the inspection robot 100 to traverse betweenpipes 502; on top of a single pipe 502 or on top of a span of pipes 502;along the exterior of a pipe, tube, or tank; and/or along the interiorof a pipe, tube, or tank.

One skilled in the art will appreciate that a great variety of differentguiding features 2052 may be used to accommodate the different surfacecharacteristics to which the robotic vehicle may be applied. In certainembodiments, combinations of features provide for the inspection robot100 to traverse multiple surfaces for a single inspection operation,reducing change-time for the wheels and the like. In certainembodiments, chamfer angles, radius of curvature, vertical depth ofchamfers or curves, and horizontal widths of chamfers or curves areselectable to accommodate the sizing of the objects to be traversedduring inspection operations. It can be seen that the down forceprovided by the magnet 6 combined with the shaping of the enclosure 3guiding features 2052 combine to provide for self-alignment of theinspection robot 100 on the surface 500, and additionally provide forprotection of the magnet 6 from exposure to shock, impacts, and/ormaterials that may be present on the inspection surface.

Additionally or alternatively, guiding features may be selectable forthe inspection surface—for example multiple enclosures and/or multiplewheel assemblies may be present for an inspection operation, and asuitable one of the multiple enclosures provided according to thecurvature of surfaces present, the spacing of pipes, the presence ofobstacles, or the like. In certain embodiments, an enclosure 3 may havean outer layer (e.g., a removable layer—not shown)—for example a snapon, slide over, coupled with set screws, or other coupling mechanism forthe outer layer, such that just an outer portion of the enclosure ischangeable to provide the guiding features. In certain embodiments, theouter layer may be a non-ferrous material (e.g., making installation andchanges of the outer layer more convenient in the presence to themagnet, which may complicate quick changes of a fully ferromagneticenclosure 3), such as a plastic, elastomeric material, aluminum, or thelike. In certain embodiments, the outer layer may be a 3-D printablematerial (e.g., plastics, ceramics, or any other 3-D printable material)where the outer layer can be constructed at an inspection location afterthe environment of the inspection surface 500 is determined. An exampleincludes the controller 802 (e.g., reference FIG. 6 and the relateddescription) structured to accept inspection parameters (e.g., pipespacing, pipe sizes, tank dimensions, etc.), and to provide a command toa 3-D printer responsive to the command to provide an outer layerconfigured for the inspection surface 500. In certain embodiments, thecontroller 802 further accepts an input for the wheel definition (e.g.,where selectable wheel sizes, clearance requirements for the inspectionrobot 100, or other parameters not necessarily defined by the inspectionsurface 500), and further provides the command to the 3-D printer, toprovide an outer layer configured for the inspection surface 500 and thewheel definition.

An example splined hub 8 design of the wheel assembly may enable modularre-configuration of the wheel, enabling each component to be easilyswitched out to accommodate different operating environments (e.g.,ferromagnetic surfaces with different permeability, different physicalcharacteristics of the surface, and the like). For instance, enclosureswith different guiding features may be exchanged to accommodatedifferent surface features, such as where one wheel configuration workswell for a first surface characteristic (e.g., a wall with tightlyspaced small pipes) and a second wheel configuration works well for asecond surface characteristic (e.g., a wall with large pipes). Themagnet 6 may also be exchanged to adjust the magnetic strength availablebetween the wheel assembly and the surface, such as to accommodatedifferent dimensional characteristics of the surface (e.g., featuresthat prevent close proximity between the magnet 6 and a surfaceferromagnetic material), different permeability of the surface material,and the like. Further, one or both enclosures 3 may be made offerromagnetic material, such as to direct the flux lines of the magnettoward a surface upon which the robotic vehicle is riding, to direct theflux lines of the magnet away from other components of the roboticvehicle, and the like, enabling the modular wheel configuration to befurther configurable for different ferromagnetic environments andapplications.

In summary, an example robotic vehicle 100 includes sensor sleds havingthe following properties capable of providing a number of sensors forinspecting a selected object or surface, including a soft or hard bottomsurface, including a bottom surface that matches an inspection surface(e.g., shape, contact material hardness, etc.), having a curved surfaceand/or ramp for obstacle clearance (including a front ramp and/or a backramp), includes a column and/or couplant insert (e.g., a cone positionedwithin the sled, where the sensor couples to the cone) that retainscouplant, improves acoustic coupling between the sensor and the surface,and/or assists in providing a consistent distance between the surfaceand the sensor; a plurality of pivot points between the main body(housing) 102 and the sled 1 to provide for surface orientation,improved obstacle traversal, and the like, a sled 1 having a mountingposition configured to receive multiple types of sensors, and/or magnetsin the sled to provide for control of downforce and/or stabilizedpositioning between the sensor and the surface. In certainimplementations of the present invention, it is advantageous to not onlybe able to adjust spacing between sensors but also to adjust theirangular position relative to the surface being inspected. The presentinvention may achieve this goal by implementing systems having severaltranslational and rotational degrees of freedom.

Referencing FIG. 2, an example payload 2 includes selectable spacingbetween sleds 1, for example to provide selectable sensor spacing. Incertain embodiments, spacing between the sensors may be adjusted using alockable translational degree of freedom such as a set screw allowingfor the rapid adjustment of spacing. Additionally or alternatively, anycoupling mechanism between the arm 20 and the payload 2 is contemplatedherein. In certain embodiments, a worm gear or other actuator allows forthe adjustment of sensor spacing by a controller and/or in real timeduring operations of the system 100. In certain embodiments, the payload2 includes a shaft 19 whereupon sleds 1 are mounted (e.g., via the arms20). In these embodiments, the sensor mounts 14 are mounted on a shaft19. The example of FIG. 2 includes a shaft cap 15 providing structuralsupport to a number of shafts of the payload 2. In the example of FIG.2, two shafts are utilized to mount the payload 2 onto the housing 102,and one shaft 19 is utilized to mount the arms 20 onto the payload 2.The arrangement utilizing a payload 2 is a non-limiting example, thatallows multiple sensors and sleds 1 to be configured in a particulararrangement, and rapidly changed out as a group (e.g., swapping out afirst payload and set of sensors for a second payload and set ofsensors, thereby changing an entire sensor arrangement in a singleoperation). However, in certain embodiments one or more of the payload2, arms 20, and/or sleds 1 may be fixedly coupled to the respectivemounting features, and numerous benefits of the present disclosure arenevertheless achieved in such embodiments.

During operation, an example system 100 encounters obstacles on thesurface of the structure being evaluated, and the pivots 16, 17, 18provide for movement of the arm 20 to traverse the obstacle. In certainembodiments, the system 100 is a modular design allowing various degreesof freedom of movement of sleds 1, either in real-time (e.g., during aninspection operation) and/or at configuration time (e.g., an operator orcontroller adjusts sensor or sled positions, down force, ramp shapes ofsleds, pivot angles of pivots 16, 17, 18 in the system 100, etc.) beforean inspection operation or a portion of an inspection operation, andincluding at least the following degrees of freedom: translation (e.g.,payload 2 position relative to the housing 102); translation of the sledarm 20 relative to the payload 2, rotation of the sled arm 20, rotationof the sled arm 20 mount on the payload 2, and/or rotation of the sled 1relative to the sled arm 20.

In certain embodiments, a system 100 allows for any one or more of thefollowing adjustments: spacing between sensors (perpendicular to thedirection of inspection motion, and/or axially along the direction ofthe inspection motion); adjustments of an angle of the sensor to anouter diameter of a tube or pipe; momentary or longer term displacementto traverse obstacles; provision of an arbitrary number and positioningof sensors; etc.

An example inspection robot 100 may utilize downforce capabilities forsensor sleds 1, such as to control proximity and lateral stabilizationof sensors. For instance, an embedded magnet (not shown) positionedwithin the sled 1 may provide passive downforce that increasesstabilization for sensor alignment. In another example, the embeddedmagnet may be an electromagnet providing active capability (e.g.,responsive to commands from a controller 802—reference FIG. 6) thatprovide adjustable or dynamic control of the downforce provided to thesensor sled. In another example, magnetic downforce may be providedthrough a combination of a passive permanent magnet and an activeelectromagnet, providing a default minimum magnetic downforce, but withfurther increases available through the active electromagnet. Inembodiments, the electromagnet may be controlled by a circuit where thedownforce is set by the operator, controlled by an on-board processor,controlled by a remote processor (e.g., through wirelesscommunications), and the like, where processor control may utilizesensor data measurements to determine the downforce setting. Inembodiments, downforce may be provided through suction force, springforce, and the like. In certain embodiments, downforce may be providedby a biasing member, such as a torsion spring or leaf spring, withactive or passive control of the downforce—for example positioning atension or confinement of the spring to control the downforce. Incertain embodiments, the magnet, biasing member, or other downforceadjusting member may adjust the downforce on the entire sled 1, on anentire payload 2, and/or just on the sensor (e.g., the sensor has someflexibility to move within the sled 1, and the downforce adjustment actson the sensor directly).

An example system 100 includes an apparatus 800 (reference FIG. 6 andthe disclosure referencing FIG. 6) for providing enhanced inspectioninformation, including position-based information. The apparatus 800 andoperations to provide the position-based information are described inthe context of a particular physical arrangement of an industrial systemfor convenient illustration, however any physical arrangement of anindustrial system is contemplated herein. Referencing FIG. 3, an examplesystem includes a number of pipes 502—for example vertically arrangedpipes such as steam pipes in a power plant, pipes in a cooling tower,exhaust or effluent gas pipes, or the like. The pipes 502 in FIG. 3 arearranged to create a tower having a circular cross-section for ease ofdescription. In certain embodiments, periodic inspection of the pipes isutilized to ensure that pipe degradation is within limits, to ensureproper operation of the system, to determine maintenance and repairschedules, and/or to comply with policies or regulations. In the exampleof FIG. 3, an inspection surface 500 includes the inner portion of thetower, whereby an inspection robot 100 traverses the pipes 502 (e.g.,vertically, inspecting one or more pipes on each vertical run). Anexample inspection robot 100 includes configurable payloads 2, and mayinclude ultra-sonic sensors (e.g., to determine wall thickness and/orpipe integrity), magnetic sensors (e.g., to determine the presenceand/or thickness of a coating on a pipe), cameras (e.g., to provide forvisual inspection, including in EM ranges outside of the visual range,temperatures, etc.), composition sensors (e.g., gas chromatography inthe area near the pipe, spectral sensing to detect leaks or anomalousoperation, etc.), temperature sensing, pressure sensing (ambient and/orspecific pressures), vibration sensing, density sensing, etc. The typeof sensing performed by the inspection robot 100 is not limiting to thepresent disclosure except where specific features are described inrelation to specific sensing challenges and opportunities for thosesensed parameters as will be understood to one of skill in the arthaving the benefit of the disclosures herein.

In certain embodiments, the inspection robot 100 has alternatively oradditionally, payload(s) 2 configured to provide for marking of aspectsof the inspection surface 500 (e.g., a paint sprayer, an invisible or UVink sprayer, and/or a virtual marking device configured to mark theinspection surface 500 in a memory location of a computing device butnot physically), to repair a portion of the inspection surface 500(e.g., apply a coating, provide a welding operation, apply a temperaturetreatment, install a patch, etc.), and/or to provide for a cleaningoperation. Referencing FIG. 4, an example inspection robot 100 isdepicted in position on the inspection surface 500 at a location. In theexample, the inspection robot 100 traverses vertically and is positionedbetween two pipes 502, with payloads 2 configured to clean, sense,treat, and/or mark two adjacent pipes 502 in a single inspection run.The inspection robot 100 in the example includes two payloads 2 at the“front” (ahead of the robot housing in the movement direction) and twopayloads 2 at the “rear” (behind the robot housing in the movementdirection). The inspection robot 100 may include any arrangement ofpayloads 2, including just one or more payloads in front or behind, justone or more payloads off to either or both sides, and combinations ofthese. Additionally or alternatively, the inspection robot 100 may bepositioned on a single pipe, and/or may traverse between positionsduring an inspection operation, for example to inspect selected areas ofthe inspection surface 500 and/or to traverse obstacles which may bepresent.

In certain embodiments, a “front” payload 2 includes sensors configuredto determine properties of the inspection surface, and a “rear” payload2 includes a responsive payload, such as an enhanced sensor, a cleaningdevice such as a sprayer, scrubber, and/or scraper, a marking device,and/or a repair device. The front-back arrangement of payloads 2provides for adjustments, cleaning, repair, and/or marking of theinspection surface 500 in a single run—for example where an anomaly,gouge, weld line, area for repair, previously repaired area, pastinspection area, etc., is sensed by the front payload 2, the anomaly canbe marked, cleaned, repaired, etc. without requiring an additional runof the inspection robot 100 or a later visit by repair personnel. Inanother example, a first calibration of sensors for the front payloadmay be determined to be incorrect (e.g., a front ultra-sonic sensorcalibrated for a particular coating thickness present on the pipes 502)and a rear sensor can include an adjusted calibration to account for thedetected aspect (e.g., the rear sensor calibrated for the observedthickness of the coating). In another example, certain enhanced sensingoperations may be expensive, time consuming, consume more resources(e.g., a gamma ray source, an alternate coupling such as a non-water oroil-based acoustic coupler, require a high energy usage, require greaterprocessing resources, and/or incur usage charges to an inspection clientfor any reason) and the inspection robot 100 can thereby only utilizethe enhanced sensing operations selectively and in response to observedconditions.

Referencing FIG. 5, a location 702 on the inspection surface 500 isidentified for illustration. In certain embodiments, the inspectionrobot 100 and/or apparatus 800 includes a controller 802 having a numberof circuits structured to functionally execute operations of thecontroller 802. The controller 802 may be a single device (e.g., acomputing device present on the robot 100, a computing device incommunication with the robot 100 during operations and/orpost-processing information communicated after inspection operations,etc.) and/or a combination of devices, such as a portion of thecontroller 802 positioned on the robot 100, a portion of the controller802 positioned on a computing device in communication with the robot100, a portion of the controller 802 positioned on a handheld device(not shown) of an inspection operator, and/or a portion of thecontroller 802 positioned on a computing device networked with one ormore of the preceding devices. Additionally or alternatively, aspects ofthe controller 802 may be included on one or more logic circuits,embedded controllers, hardware configured to perform certain aspects ofthe controller 802 operations, one or more sensors, actuators, networkcommunication infrastructure (including wired connections, wirelessconnections, routers, switches, hubs, transmitters, and/or receivers),and/or a tether between the robot 100 and another computing device. Thedescribed aspects of the example controller 802 are non-limitingexamples, and any configuration of the robot 100 and devices incommunication with the robot 100 to perform all or selected ones ofoperations of the controller 802 are contemplated herein as aspects ofan example controller 802.

An example controller 802 includes an inspection data circuit 804 thatinterprets inspection data 812—for example sensed information fromsensors mounted on the payload and determining aspects of the inspectionsurface 500, the status, deployment, and/or control of marking devices,cleaning devices, and/or repair devices, and/or post-processedinformation from any of these such as a wall thickness determined fromultra-sonic data, temperature information determined from imaging data,and the like. The example controller 802 further includes a robotpositioning circuit 806 that interprets position data 814. An examplerobot positioning circuit 806 determines position data by any availablemethod, including at least triangulating (or other positioning methods)from a number of available wireless devices (e.g., routers available inthe area of the inspection surface 500, intentionally positionedtransmitters/transceivers, etc.), a distance of travel measurement(e.g., a wheel rotation counter which may be mechanical,electro-magnetic, visual, etc.; a barometric pressure measurement;direct visual determinations such as radar, Lidar, or the like), areference measurement (e.g., determined from distance to one or morereference points); a time-based measurement (e.g., based upon time andtravel speed); and/or a dead reckoning measurement such as integrationof detection movements. In the example of FIG. 5, a position measurementmay include a height determination combined with an azimuthal anglemeasurement and/or a pipe number value such that the inspection surface500 location is defined thereby. Any coordinate system and/or positiondescription system is contemplated herein. In certain embodiments, thecontroller 802 includes a processed data circuit 808 that combines theinspection data 812 with the position data 814 to determineposition-based inspection data. The operations of the processed datacircuit 808 may be performed at any time—for example during operationsof the inspection robot 100 such that inspection data 812 is stored withposition data 814, during a post-processing operation which may becompleted separately from the inspection robot 100, and/or which may beperformed after the inspection is completed, and/or which may becommenced while the inspection is being performed. In certainembodiments, the linking of the position data 814 with the inspectiondata 812 may be performed if the linked position-inspection data isrequested—for example upon a request by a client for an inspection map818. In certain embodiments, portions of the inspection data 812 arelinked to the position data 814 at a first time, and other portions ofthe inspection data 812 are linked to the position data 814 at a latertime and/or in response to post-processing operations, an inspection map818 request, or other subsequent event.

The example controller 802 further includes an inspection visualizationcircuit 810 that determines the inspection map 818 in response to theinspection data 812 and the position data 814, for example usingpost-processed information from the processed data circuit 808. In afurther example, the inspection visualization circuit 810 determines theinspection map 818 in response to an inspection visualization request820, for example from a client computing device 826. In the example, theclient computing device 826 may be communicatively coupled to thecontroller 802 over the internet, a network, through the operations of aweb application, and the like. In certain embodiments, the clientcomputing device 826 securely logs in to control access to theinspection map 818, and the inspection visualization circuit 810 mayprevent access to the inspection map 818, and/or provide only portionsof the inspection map 818, depending upon the successful login from theclient computing device 826, the authorizations for a given user of theclient computing device 826, and the like.

In certain embodiments, the inspection visualization circuit 810 and/orinspection data circuit 804 further accesses system data 816, such as atime of the inspection, a calendar date of the inspection, the robot 100utilized during the inspection and/or the configurations of the robot100, a software version utilized during the inspection, calibrationand/or sensor processing options selected during the inspection, and/orany other data that may be of interest in characterizing the inspection,that may be requested by a client, that may be required by a policyand/or regulation, and/or that may be utilized for improvement tosubsequent inspections on the same inspection surface 500 or anotherinspection surface. In certain embodiments, the processed data circuit808 combines the system data 816 with the processed data for theinspection data 812 and/or the position data 814, and/or the inspectionvisualization circuit incorporates the system data 816 or portionsthereof into the inspection map 818. In certain embodiments, any or allaspects of the inspection data 812, position data 814, and/or systemdata 816 may be stored as meta-data (e.g., not typically available fordisplay), may be accessible in response to prompts, further selections,and/or requests from the client computing device 826, and/or may beutilized in certain operations with certain identifiable aspects removed(e.g., to remove personally identifiable information or confidentialaspects) such as post-processing to improve future inspectionoperations, reporting for marketing or other purposes, or the like.

In certain embodiments, the inspection visualization circuit 810 isfurther responsive to a user focus value 822 to update the inspectionmap 818 and/or to provide further information (e.g., focus data 824) toa user, such as a user of the client computing device 826. For example,a user focus value 822 (e.g., a user mouse position, menu selection,touch screen indication, keystroke, or other user input value indicatingthat a portion of the inspection map 818 has received the user focus)indicates that a location 702 of the inspection map 818 has the userfocus, and the inspection visualization circuit 810 generates the focusdata 824 in response to the user focus value 822, including potentiallythe location 702 indicated by the user focus value 822.

Referencing FIG. 7, an example inspection map 818 is depicted. In theexample, the inspection surface 500 may be similar to that depicted inFIG. 3—for example the interior surface of tower formed by a number ofpipes to be inspected. The example inspection map 818 includes anazimuthal indication 902 and a height indication 904, with data from theinspection depicted on the inspection map 818 (e.g., shading at 906indicating inspection data corresponding to that visual location).Example and non-limiting inspection maps 818 include numeric valuesdepicted on the visualization, colors, shading or hatching, and/or anyother visual depiction method. In certain embodiments, more than oneinspection dimension may be visualized (e.g., temperatures and wallthickness), and/or the inspection dimension may be selected or changedby the user. Additionally or alternatively, physical elements such asobstacles, build up on the inspection surface, weld lines, gouges,repaired sections, photos of the location (e.g., the inspection map 818laid out over a panoramic photograph of the inspection surface 500 withdata corresponding to the physical location depicted), may be depictedwith or as a part of the inspection map 818. Additionally oralternatively, visual markers may be positioned on the inspection map818—for example a red “X” (or any other symbol, including a color,bolded area, highlight, image data, a thumbnail, etc.) at a location ofinterest on the map—which marking may be physically present on theactual inspection surface 500 or only virtually depicted on theinspection map 818. It can be seen that the inspection map 818 providesfor a convenient and powerful reference tool for a user to determine theresults of the inspection operation and plan for future maintenance,repair, or inspections, as well as planning logistics in response to thenumber of aspects of the system requiring further work or analysis andthe location of the aspects requiring further work or analysis.Accordingly, inspection results can be analyzed more quickly, regulatoryor policy approvals and system up-time can be restored more quickly (ifthe system was shut-down for the inspection), configurations of aninspection robot 100 for a future inspection can be performed morequickly (e.g. preparing payload 2 configurations, obstacle management,and/or sensor selection or calibration), any of the foregoing can beperformed with greater confidence that the results are reliable, and/orany combinations of the foregoing. Additionally or alternatively, lessinvasive operations can be performed, such as virtual marking whichwould not leave marks on the inspection surface 500 that might beremoved (e.g., accidentally) before they are acted upon, which mayremain after being acted upon, or which may create uncertainty as towhen the marks were made over the course of multiple inspections andmarking generations.

Referencing FIG. 8, an illustrative example inspection map 818 havingfocus data 824 is depicted. The example inspection map 818 is responsiveto a user focus value 822, such as a mouse cursor 1002 hovering over aportion of the inspection map 818. In the example, the focus data 824comes up as a tool-tip, although any depiction operations such as outputto a file, populating a static window for focus data 824, or any otheroperations known in the art are contemplated herein. The example focusdata 824 includes a date (e.g., of the inspection), a time (e.g., of theinspection), the sensor calibrations utilized for the inspection, andthe time to repair (e.g., down-time that would be required, actualrepair time that would be required, the estimated time until the portionof the inspection surface 500 will require a repair, or any otherdescription of a “time to repair”). The depicted focus data 824 is anon-limiting example, and any other information of interest may beutilized as focus data 824. In certain embodiments, a user may selectthe information, or portions thereof, utilized on the inspection map818—including at least the axes 902, 904 (e.g., units, type ofinformation, relative versus absolute data, etc.) and the depicted data(e.g., units, values depicted, relative versus absolute values,thresholds or cutoffs of interest, processed values such as virtuallydetermined parameters, and/or categorical values such as “PASSED” or“FAILED”). Additionally or alternatively, a user may select theinformation, or portions thereof, utilized as the focus data 824.

In certain embodiments, an inspection map 818 (or display) provides anindication of how long a section of the inspection surface 500 isexpected to continue under nominal operations, how much material shouldbe added to a section of the inspection surface 500 (e.g., a repaircoating or other material), and/or the type of repair that is needed(e.g., wall thickness correction, replacement of a coating, fixing ahole, breach, rupture, etc.).

In embodiments, the robotic vehicle may incorporate a number of sensorsdistributed across a number of sensor sleds 1, such as with a singlesensor mounted on a single sensor sled 1, a number of sensors mounted ona single sensor sled 1, a number of sensor sleds 1 arranged in a linearconfiguration perpendicular to the direction of motion (e.g.,side-to-side across the robotic vehicle), arranged in a linearconfiguration along the direction of motion (e.g., multiple sensors on asensor sled 1 or multiple sensor sleds 1 arranged to cover the samesurface location one after the other as the robotic vehicle travels).Additionally or alternatively, a number of sensors may be arranged in atwo-dimensional surface area, such as by providing sensor coverage in adistributed manner horizontally and/or vertically (e.g., in thedirection of travel), including offset sensor positions (e.g., referenceFIG. 12). In certain embodiments, the utilization of payloads 2 withsensor sleds mounted thereon enables rapid configuration of sensorplacement as desired, sleds 1 on a given payload 2 can be furtheradjusted, and/or sensor(s) on a given sled can be changed or configuredas desired.

In certain embodiments, two payloads 2 side-by-side allow for a widehorizontal coverage of sensing for a given travel of the inspectionrobot 100—for example as depicted in FIG. 1. In certain embodiments, apayload 2 is coupled to the inspection robot 100 with a pin or otherquick-disconnect arrangement, allowing for the payload 2 to be removed,to be reconfigured separately from the inspection robot 100, and/or tobe replaced with another payload 2 configured in a desired manner. Thepayload 2 may additionally have a couplant connection to the inspectionrobot 100 (e.g., reference FIG. 29—where a single couplant connectionprovides coupling connectivity to all sleds 1A and 1B) and/or anelectrical connection to the inspection robot 100. Each sled may includea couplant connection conduit where the couplant connection conduit iscoupled to a payload couplant connection at the upstream end and iscoupled to the couplant entry of the cone at the downstream end.Multiple payload couplant connections on a single payload may be coupledtogether to form a single couplant connection between the payload andthe inspection robot. The single couplant connection per payloadfacilitates the changing of the payload without having toconnect/disconnect the couplant line connections at each sled. Thecouplant connection conduit between the payload couplant connection andthe couplant entry of the cone facilitates connecting/disconnecting asled from a payload without having to connect/disconnect the couplantconnection conduit from the couplant entry of the cone. The couplantand/or electrical connections may include power for the sensors asrequired, and/or communication coupling (e.g., a datalink or networkconnection). Additionally or alternatively, sensors may communicatewirelessly to the inspection robot 100 or to another computing device,and/or sensors may store data in a memory associated with the sensor,sled 1, or payload 2, which may be downloaded at a later time. Any otherconnection type required for a payload 2, such as compressed air, paint,cleaning solutions, repair spray solutions, or the like, may similarlybe coupled from the payload 2 to the inspection robot 100.

The horizontal configuration of sleds 1 (and sensors) is selectable toachieve the desired inspection coverage. For example, sleds 1 may bepositioned to provide a sled running on each of a selected number ofpipes of an inspection surface, positioned such that several sleds 1combine on a single pipe of an inspection surface (e.g., providinggreater radial inspection resolution for the pipe), and/or at selectedhorizontal distances from each other (e.g., to provide 1 inchresolution, 2 inch resolution, 3 inch resolution, etc.). In certainembodiments, the degrees of freedom of the sensor sleds 1 (e.g., frompivots 16, 17, 18) allow for distributed sleds 1 to maintain contact andorientation with complex surfaces.

In certain embodiments, sleds 1 are articulable to a desired horizontalposition. For example, quick disconnects may be provided (pins, claims,set screws, etc.) that allow for the sliding of a sled 1 to any desiredlocation on a payload 2, allowing for any desired horizontal positioningof the sleds 1 on the payload 2. Additionally or alternatively, sleds 1may be movable horizontally during inspection operations. For example, aworm gear or other actuator may be coupled to the sled 1 and operable(e.g., by a controller 802) to position the sled 1 at a desiredhorizontal location. In certain embodiments, only certain ones of thesleds 1 are moveable during inspection operations—for example outersleds 1 for maneuvering past obstacles. In certain embodiments, all ofthe sleds 1 are moveable during inspection operations—for example tosupport arbitrary inspection resolution (e.g., horizontal resolution,and/or vertical resolution), to configure the inspection trajectory ofthe inspection surface, or for any other reason. In certain embodiments,the payload 2 is horizontally moveable before or during inspectionoperations. In certain embodiments, an operator configures the payload 2and/or sled 1 horizontal positions before inspection operations (e.g.,before or between inspection runs). In certain embodiments, an operatoror a controller 802 configures the payload 2 and/or sled 1 horizontalpositions during inspection operations. In certain embodiments, anoperator can configure the payload 2 and/or sled 1 horizontal positionsremotely, for example communicating through a tether or wirelessly tothe inspection robot.

The vertical configuration of sleds 1 is selectable to achieve thedesired inspection coverage (e.g., horizontal resolution, verticalresolution, and/or redundancy). For example, referencing FIG. 11,multiple payloads 2 are positioned on a front side of the inspectionrobot 100, with forward payloads 2006 and rear payloads 1402. In certainembodiments, a payload 2 may include a forward payload 2006 and a rearpayload 1402 in a single hardware device (e.g., with a single mountingposition to the inspection robot 100), and/or may be independentpayloads 2 (e.g., with a bracket extending from the inspection robot 100past the rear payload 1402 for mounting the forward payloads 2006). Inthe example of FIG. 11, the rear payload 1402 and forward payload 2006include sleds 1 mounted thereupon which are in vertical alignment1302—for example a given sled 1 of the rear payload 1402 traverses thesame inspection position (or horizontal lane) of a corresponding sled 1of the forward payload 2006. The utilization of aligned payloads 2provides for a number of capabilities for the inspection robot 100,including at least: redundancy of sensing values (e.g., to develophigher confidence in a sensed value); the utilization of more than onesensing calibration for the sensors (e.g., a front sensor utilizes afirst calibration set, and a rear sensor utilizes a second calibrationset); the adjustment of sensing operations for a rear sensor relative toa forward sensor (e.g., based on the front sensed parameter, a rearsensor can operate at an adjusted range, resolution, sampling rate, orcalibration); the utilization of a rear sensor in response to a frontsensor detected value (e.g., a rear sensor may be a high costsensor—either high power, high computing/processing requirements, anexpensive sensor to operate, etc.) where the utilization of the rearsensor can be conserved until a front sensor indicates that a value ofinterest is detected; the operation of a repair, marking, cleaning, orother capability rear payload 1402 that is responsive to the detectedvalues of the forward payload 2006; and/or for improved verticalresolution of the sensed values (e.g., if the sensor has a givenresolution of detection in the vertical direction, the front and rearpayloads can be operated out of phase to provide for improved verticalresolution).

In another example, referencing FIG. 12, multiple payloads 2 arepositioned on the front of the inspection robot 100, with sleds 1mounted on the front payload 2006 and rear payload 1402 that are notaligned (e.g., lane 1304 is not shared between sleds of the frontpayload 2006 and rear payload 1402). The utilization of not alignedpayloads 2 allows for improved resolution in the horizontal directionfor a given number of sleds 1 mounted on each payload 2. In certainembodiments, not aligned payloads may be utilized where the hardwarespace on a payload 2 is not sufficient to conveniently provide asufficient number or spacing of sleds 1 to achieve the desiredhorizontal coverage. In certain embodiments, not aligned payloads may beutilized to limit the number of sleds 1 on a given payload 2, forexample to provide for a reduced flow rate of couplant through a givenpayload-inspection robot connection, to provide for a reduced load on anelectrical coupling (e.g., power supply and/or network communicationload) between a given payload and the inspection robot. While theexamples of FIGS. 11 and 12 depict aligned or not aligned sleds forconvenience of illustration, a given inspection robot 100 may beconfigured with both aligned and not aligned sleds 1, for example toreduce mechanical loads, improve inspection robot balance, in responseto inspection surface constraints, or the like.

It can be seen that sensors may be modularly configured on the roboticvehicle to collect data on specific locations across the surface oftravel (e.g., on a top surface of an object, on the side of an object,between objects, and the like), repeat collection of data on the samesurface location (e.g., two sensors serially collecting data from thesame location, either with the same sensor type or different sensortypes), provide predictive sensing from a first sensor to determine if asecond sensor should take data on the same location at a second timeduring a single run of the robotic vehicle (e.g., an ultra-sonic sensormounted on a leading sensor sled taking data on a location determinesthat a gamma-ray measurement should be taken for the same location by asensor mounted on a trailing sensor sled configured to travel over thesame location as the leading sensor), provide redundant sensormeasurements from a plurality of sensors located in leading and trailinglocations (e.g., located on the same or different sensor sleds to repeatsensor data collection), and the like.

In certain embodiments, the robotic vehicle includes sensor sleds withone sensor and sensor sleds with a plurality of sensors. A number ofsensors arranged on a single sensor sled may be arranged with the samesensor type across the direction of robotic vehicle travel (e.g.,perpendicular to the direction of travel, or “horizontal”) to increasecoverage of that sensor type (e.g., to cover different surfaces of anobject, such as two sides of a pipe), arranged with the same sensor typealong the direction of robotic vehicle travel (e.g., parallel to thedirection of travel, or “vertical”) to provide redundant coverage ofthat sensor type over the same location (e.g., to ensure data coverage,to enable statistical analysis based on multiple measurements over thesame location), arranged with a different sensor type across thedirection of robotic vehicle travel to capture a diversity of sensordata in side-by-side locations along the direction of robotic vehicletravel (e.g., providing both ultra-sonic and conductivity measurementsat side-by-side locations), arranged with a different sensor type alongthe direction of robotic vehicle travel to provide predictive sensingfrom a leading sensor to a trailing sensor (e.g., running a trailinggamma-ray sensor measurement only if a leading ultra-sonic sensormeasurement indicates the need to do so), combinations of any of these,and the like. The modularity of the robotic vehicle may permitexchanging sensor sleds with the same sensor configuration (e.g.,replacement due to wear or failure), different sensor configurations(e.g., adapting the sensor arrangement for different surfaceapplications), and the like.

Providing for multiple simultaneous sensor measurements over a surfacearea, whether for taking data from the same sensor type or fromdifferent sensor types, provides the ability to maximize the collectionof sensor data in a single run of the robotic vehicle. If the surfaceover which the robotic vehicle was moving were perfectly flat, thesensor sled could cover a substantial surface with an array of sensors.However, the surface over which the robotic vehicle travels may behighly irregular, and have obstacles over which the sensor sleds mustadjust, and so the preferred embodiment for the sensor sled isrelatively small with a highly flexible orientation, as describedherein, where a plurality of sensor sleds is arranged to cover an areaalong the direction of robotic vehicle travel. Sensors may bedistributed amongst the sensor sleds as described for individual sensorsleds (e.g., single sensor per sensor sled, multiple sensors per sensorsled (arranged as described herein)), where total coverage is achievedthrough a plurality of sensor sleds mounted to the robotic vehicle. Onesuch embodiment, as introduced herein, such as depicted in FIG. 1,comprises a plurality of sensor sleds arranged linearly across thedirection of robotic vehicle travel, where the plurality of sensor sledsis capable of individually adjusting to the irregular surface as therobotic vehicle travels. Further, each sensor sled may be positioned toaccommodate regular characteristics in the surface (e.g., positioningsensor sleds to ride along a selected portion of a pipe aligned alongthe direction of travel), to provide for multiple detections of a pipeor tube from a number of radial positions, sensor sleds may be shaped toaccommodate the shape of regular characteristics in the surface (e.g.,rounded surface of a pipe), and the like. In this way, the sensor sledarrangement may accommodate both the regular characteristics in thesurface (e.g., a series of features along the direction of travel) andirregular characteristics along the surface (e.g., obstacles that thesensor sleds flexibly mitigate during travel along the surface).

Although FIG. 1 depicts a linear arrangement of sensor sleds with thesame extension (e.g., the same connector arm length), another examplearrangement may include sensor sleds with different extensions, such aswhere some sensor sleds are arranged to be positioned further out,mounted on longer connection arms. This arrangement may have theadvantage of allowing a greater density of sensors across theconfiguration, such as where a more leading sensor sled could bepositioned linearly along the configuration between two more trailingsensor sleds such that sensors are provided greater linear coverage thanwould be possible with all the sensor sleds positioned side-by-side.This configuration may also allow improved mechanical accommodationbetween the springs and connectors that may be associated withconnections of sensor sleds to the arms and connection assembly (e.g.,allowing greater individual movement of sensor sleds without the sensorsleds making physical contact with one another).

Referring to FIG. 11, an example configuration of sensor sleds includesthe forward payload 2006 ahead of the rear payload 1402, such as whereeach utilizes a payload mount assembly 6900 (see FIG. 32) for mountingthe payloads. Again, although FIG. 11 depicts the sensor sled arrayswith equal lengths, different lengths, as shown in FIG. 12, may beutilized to position, for instance, sensor sleds of sensor sled array1402 in intermediate positions between rear sensor sleds of rear payload1402 and forward sensor sleds of the forward payload 2006. As was thecase with the arrangement of a plurality of sensors on a single sensorsled to accommodate different coverage options (e.g., maximizingcoverage, predictive capabilities, redundancy, and the like), theextended area configuration of sensors in this multiple sensor sledarray arrangement allows similar functionality. For instance, a sensorsled positioned in a lateral position on the forward payload 2006 mayprovide redundant or predictive functionality for another sensor sledpositioned in the same lateral position on the rear payload 1402. In thecase of a predictive functionality, the greater travel distance affordedby the separation between a sensor sled mounted on the front payload2006 and a sensor sled mounted on the rear payload 1402 may provide foradditional processing time for determining, for instance, whether thesensor in the trailing sensor sled should be activated. For example, theleading sensor collects sensor data and sends that data to a processingfunction (e.g., wired communication to on-board or external processing,wireless communication to external processing), the processor takes aperiod of time to determine if the trailing sensor should be activated,and after the determination is made, activates the trailing sensor. Theseparation of the two sensors, divided by the rate of travel of therobotic vehicle, determines the time available for processing. Thegreater the distance, the greater the processing time allowed. Referringto FIG. 13, in another example, distance is increased further byutilizing a trailing payload 2008, thus increasing the distance andprocessing time further. Additionally or alternatively, the hardwarearrangement of FIG. 13 may provide for more convenient integration ofthe trailing payload 2008 rather than having multiple payloads 1402,2006 in front of the inspection robot 100. In certain embodiments,certain operations of a payload 2 may be easier or more desirable toperform on a trailing side of the inspection robot 100—such as sprayingof painting, marking, or repair fluids, to avoid the inspection robot100 having to be exposed to such fluids as a remaining mist, by gravityflow, and/or having to drive through the painted, cleaned, or repairedarea. In certain embodiments, an inspection robot 100 may additionallyor alternatively include both multiple payloads 1402, 2006 in front ofthe inspection robot (e.g., as depicted in FIGS. 11 and 12) and/or oneor more trailing payloads (e.g., as depicted in FIG. 13).

In another example, the trailing payload 2008 may provide a greaterdistance for functions that would benefit the system by being isolatedfrom the sensors in the forward end of the robotic vehicle. Forinstance, the robotic vehicle may provide for a marking device (e.g.,visible marker, UV marker, and the like) to mark the surface when acondition alert is detected (e.g., detecting corrosion or erosion in apipe at a level exceeding a predefined threshold, and marking the pipewith visible paint).

Embodiments with multiple sensor sled connector assemblies provideconfigurations and area distribution of sensors that may enable greaterflexibility in sensor data taking and processing, including alignment ofsame-type sensor sleds allowing for repeated measurements (e.g., thesame sensor used in a leading sensor sled as in a trailing sensor sled,such as for redundancy or verification in data taking when leading andtrailing sleds are co-aligned), alignment of different-type sensor sledsfor multiple different sensor measurements of the same path (e.g.,increase the number of sensor types taking data, have the lead sensorprovide data to the processor to determine whether to activate thetrailing sensor (e.g., ultra-sonic/gamma-ray, and the like)), off-setalignment of same-type sensor sleds for increased coverage when leadingand trailing sleds are off-set from one another with respect to travelpath, off-set alignment of different-type sensor sleds for trailingsensor sleds to measure surfaces that have not been disturbed by leadingsensor sleds (e.g., when the leading sensor sled is using a couplant),and the like.

The modular design of the robotic vehicle may provide for a systemflexible to different applications and surfaces (e.g., customizing therobot and modules of the robot ahead of time based on the application,and/or during an inspection operation), and to changing operationalconditions (e.g., flexibility to changes in surface configurations andconditions, replacement for failures, reconfiguration based on sensedconditions), such as being able to change out sensors, sleds, assembliesof sleds, number of sled arrays, and the like.

An example inspection robot utilizes a magnet-based wheel designAlthough the inspection robot may utilize flux directing ferromagneticwheel components, such as ferromagnetic magnet enclosures 3 to minimizethe strength of the extended magnetic field, ferromagnetic componentswithin the inspection robot may be exposed to a magnetic field. Onecomponent that may experience negative effects from the magnetic fieldis the gearbox, which may be mounted proximate to the wheel assembly.

Throughout the present description, certain orientation parameters aredescribed as “horizontal,” “perpendicular,” and/or “across” thedirection of travel of the inspection robot, and/or described as“vertical,” “parallel,” and/or in line with the direction of travel ofthe inspection robot. It is specifically contemplated herein that theinspection robot may be travelling vertically, horizontally, at obliqueangles, and/or on curves relative to a ground-based absolute coordinatesystem. Accordingly, except where the context otherwise requires, anyreference to the direction of travel of the inspection robot isunderstood to include any orientation of the robot—such as an inspectionrobot traveling horizontally on a floor may have a “vertical” directionfor purposes of understanding sled distribution that is in a“horizontal” absolute direction. Additionally, the “vertical” directionof the inspection robot may be a function of time during inspectionoperations and/or position on an inspection surface—for example as aninspection robot traverses over a curved surface. In certainembodiments, where gravitational considerations or other context basedaspects may indicate—vertical indicates an absolute coordinate systemvertical—for example in certain embodiments where couplant flow into acone is utilized to manage bubble formation in the cone. In certainembodiments, a trajectory through the inspection surface of a given sledmay be referenced as a “horizontal inspection lane”—for example, thetrack that the sled takes traversing through the inspection surface.

Certain embodiments include an apparatus for acoustic inspection of aninspection surface with arbitrary resolution. Arbitrary resolution, asutilized herein, includes resolution of features in geometric space witha selected resolution—for example resolution of features (e.g., cracks,wall thickness, anomalies, etc.) at a selected spacing in horizontalspace (e.g., perpendicular to a travel direction of an inspection robot)and/or vertical space (e.g., in a travel direction of an inspectionrobot). While resolution is described in terms of the travel motion ofan inspection robot, resolution may instead be considered in anycoordinate system, such as cylindrical or spherical coordinates, and/oralong axes unrelated to the motion of an inspection robot. It will beunderstood that the configurations of an inspection robot and operationsdescribed in the present disclosure can support arbitrary resolution inany coordinate system, with the inspection robot providing sufficientresolution as operated, in view of the target coordinate system.Accordingly, for example, where inspection resolution of 6-inches isdesired in a target coordinate system that is diagonal to the traveldirection of the inspection robot, the inspection robot and relatedoperations described throughout the present disclosure can supportwhatever resolution is required (whether greater than 6-inches, lessthan 6-inches, or variable resolution depending upon the location overthe inspection surface) to facilitate the 6-inch resolution of thetarget coordinate system. It can be seen that an inspection robot and/orrelated operations capable of achieving an arbitrary resolution in thecoordinates of the movement of the inspection robot can likewise achievearbitrary resolution in any coordinate system for the mapping of theinspection surface. For clarity of description, apparatus and operationsto support an arbitrary resolution are described in view of thecoordinate system of the movement of an inspection robot.

An example apparatus to support acoustic inspection of an inspectionsurface includes an inspection robot having a payload and a number ofsleds mounted thereon, with the sleds each having at least one acousticsensor mounted thereon. Accordingly, the inspection robot is capable ofsimultaneously determining acoustic parameters at a range of positionshorizontally. Sleds may be positioned horizontally at a selectedspacing, including providing a number of sleds to provide sensorspositioned radially around several positions on a pipe or other surfacefeature of the inspection surface. In certain embodiments, verticalresolution is supported according to the sampling rate of the sensors,and/or the movement speed of the inspection robot. Additionally oralternatively, the inspection robot may have vertically displacedpayloads, having an additional number of sleds mounted thereon, with thesleds each having at least one acoustic sensor mounted thereon. Theutilization of additional vertically displaced payloads can provideadditional resolution, either in the horizontal direction (e.g., wheresleds of the vertically displaced payload(s) are offset from sleds inthe first payload(s)) and/or in the vertical direction (e.g., wheresensors on sleds of the vertically displaced payload(s) are samplingsuch that sensed parameters are vertically offset from sensors on sledsof the first payload(s)). Accordingly, it can be seen that, even wherephysical limitations of sled spacing, numbers of sensors supported by agiven payload, or other considerations limit horizontal resolution for agiven payload, horizontal resolution can be enhanced through theutilization of additional vertically displaced payloads. In certainembodiments, an inspection robot can perform another inspection run overa same area of the inspection surface, for example with sleds trackingin an offset line from a first run, with positioning information toensure that both horizontal and/or vertical sensed parameters are offsetfrom the first run.

Accordingly, an apparatus is provided that achieves significantresolution improvements, horizontally and/or vertically, over previouslyknown systems. Additionally or alternatively, an inspection robotperforms inspection operations at distinct locations on a descentoperation than on an ascent operation, providing for additionalresolution improvements without increasing a number of run operationsrequired to perform the inspection (e.g., where an inspection robotascends an inspection surface, and descends the inspection surface as anormal part of completing the inspection run). In certain embodiments,an apparatus is configured to perform multiple run operations to achievethe selected resolution. It can be seen that the greater the number ofinspection runs required to achieve a given spatial resolution, thelonger the down time for the system (e.g., an industrial system) beinginspected (where a shutdown of the system is required to perform theinspection), the longer the operating time and greater the cost of theinspection, and/or the greater chance that a failure occurs during theinspection. Accordingly, even where multiple inspection runs arerequired, a reduction in the number of the inspection runs isbeneficial.

In certain embodiments, an inspection robot includes a low fluid losscouplant system, enhancing the number of sensors that are supportable ina given inspection run, thereby enhancing available sensing resolution.In certain embodiments, an inspection robot includes individual downforce support for sleds and/or sensors, providing for reduced fluidloss, reduced off-nominal sensing operations, and/or increasing theavailable number of sensors supportable on a payload, thereby enhancingavailable sensing resolution. In certain embodiments, an inspectionrobot includes a single couplant connection for a payload, and/or asingle couplant connection for the inspection robot, thereby enhancingreliability and providing for a greater number of sensors on a payloadand/or on the inspection robot that are available for inspections undercommercially reasonable operations (e.g., configurable for inspectionoperations with reasonable reliability, checking for leaks, expected tooperate without problems over the course of inspection operations,and/or do not require a high level of skill or expensive test equipmentto ensure proper operation). In certain embodiments, an inspection robotincludes acoustic sensors coupled to acoustic cones, enhancing robustdetection operations (e.g., a high percentage of valid sensing data,ease of acoustic coupling of a sensor to an inspection surface, etc.),reducing couplant fluid losses, and/or easing integration of sensorswith sleds, thereby supporting an increased number of sensors perpayload and/or inspection robot, and enhancing available sensingresolution. In certain embodiments, an inspection robot includesutilizing water as a couplant, thereby reducing fluid pumping losses,reducing risks due to minor leaks within a multiple plumbing line systemto support multiple sensors, and/or reducing the impact (environmental,hazard, clean-up, etc.) of performing multiple inspection runs and/orperforming an inspection operation with a multiplicity of acousticsensors operating.

Example and non-limiting configuration adjustments include changing ofsensing parameters such as cut-off times to observe peak values forultra-sonic processing, adjustments of rationality values forultra-sonic processing, enabling of trailing sensors or additionaltrailing sensors (e.g., X-ray, gamma ray, high resolution cameraoperations, etc.), adjustment of a sensor sampling rate (e.g., faster orslower), adjustment of fault cut-off values (e.g., increase or decreasefault cutoff values), adjustment of any transducer configurableproperties (e.g., voltage, waveform, gain, filtering operations, and/orreturn detection algorithm), and/or adjustment of a sensor range orresolution value (e.g., increase a range in response to a lead sensingvalue being saturated or near a range limit, decrease a range inresponse to a lead sensing value being within a specified range window,and/or increase or decrease a resolution of the trailing sensor). Incertain embodiments, a configuration adjustment to adjust a samplingrate of a trailing sensor includes by changing a movement speed of aninspection robot.

An example apparatus is disclosed to perform an inspection of anindustrial surface. Many industrial surfaces are provided in hazardouslocations, including without limitation where heavy or dangerousmechanical equipment operates, in the presence of high temperatureenvironments, in the presence of vertical hazards, in the presence ofcorrosive chemicals, in the presence of high pressure vessels or lines,in the presence of high voltage electrical conduits, equipment connectedto and/or positioned in the vicinity of an electrical power connection,in the presence of high noise, in the presence of confined spaces,and/or with any other personnel risk feature present. Accordingly,inspection operations often include a shutdown of related equipment,and/or specific procedures to mitigate fall hazards, confined spaceoperations, lockout-tagout procedures, or the like. In certainembodiments, the utilization of an inspection robot allows for aninspection without a shutdown of the related equipment. In certainembodiments, the utilization of an inspection robot allows for ashutdown with a reduced number of related procedures that would berequired if personnel were to perform the inspection. In certainembodiments, the utilization of an inspection robot provides for apartial shutdown to mitigate some factors that may affect the inspectionoperations and/or put the inspection robot at risk, but allows for otheroperations to continue. For example, it may be acceptable to positionthe inspection robot in the presence of high pressure or high voltagecomponents, but operations that generate high temperatures may be shutdown.

In certain embodiments, the utilization of an inspection robot providesadditional capabilities for operation. For example, an inspection robothaving positional sensing within an industrial environment can requestshutdown of only certain aspects of the industrial system that arerelated to the current position of the inspection robot, allowing forpartial operations as the inspection is performed. In another example,the inspection robot may have sensing capability, such as temperaturesensing, where the inspection robot can opportunistically inspectaspects of the industrial system that are available for inspection,while avoiding other aspects or coming back to inspect those aspectswhen operational conditions allow for the inspection. Additionally, incertain embodiments, it is acceptable to risk the industrial robot(e.g., where shutting down operations exceed the cost of the loss of theindustrial robot) to perform an inspection that has a likelihood ofsuccess, where such risks would not be acceptable for personnel. Incertain embodiments, a partial shutdown of a system has lower cost thana full shutdown, and/or can allow the system to be kept in a conditionwhere restart time, startup operations, etc. are at a lower cost orreduced time relative to a full shutdown. In certain embodiments, theenhanced cost, time, and risk of performing additional operations beyondmere shutdown, such as compliance with procedures that would be requiredif personnel were to perform the inspection, can be significant.

Referencing FIG. 14, an example apparatus 3600 to inspect a plant,industrial system, and/or inspection surface utilizing positioninformation is depicted schematically. The example apparatus 3600includes a position definition circuit 3602 that interprets positioninformation 3604, and/or determines a plant position definition 3606(e.g., a plant definition value) and an inspection robot position (e.g.,as one or more plant position values 3614) in response to the positioninformation 3604. Example and non-limiting position information 3604includes relative and/or absolute position information—for example adistance from a reference position (e.g., a starting point, stoppingpoint, known object in proximity to the plant, industrial system, and/orinspection surface, or the like). In certain embodiments, positioninformation 3604 is determinable according to a global positioningservice (GPS) device, ultra-wide band radio frequency (RF) signaling,LIDAR or other direct distance measurement devices (includingline-of-sight and/or sonar devices), aggregating from reference points(e.g., routers, transmitters, know devices in communication with theinspection robot, or the like), utilizing known obstacles as a referencepoint, encoders (e.g., a wheel counter or other device), barometricsensors (e.g., altitude determination), utilization of a known sensedvalue correlated to position (e.g., sound volume or frequency,temperature, vibration, etc.), and/or utilizing an inertial measurementunit (e.g., measuring and/or calculating utilizing an accelerometerand/or gyroscope). In certain embodiments, values may be combined todetermine the position information 3604—for example in 3-D space withoutfurther information, four distance measurements are ordinarily requiredto determine a specific position value. However, utilizing otherinformation, such as a region of the inspection surface that theinspection robot is operating on (e.g., which pipe the inspection robotis climbing), an overlay of the industrial surface over the measurementspace, a distance traveled from a reference point, a distance to areference point, etc., the number of distance measurements required todetermine a position value can be reduced to three, two, one, or eveneliminated and still position information 3604 is determinable. Incertain embodiments, the position definition circuit 3602 determines theposition information 3604 completely or partially on dead reckoning(e.g., accumulating speed and direction from a known position, and/ordirection combined with a distance counter), and/or corrects theposition information 3604 when feedback based position data (e.g., atrue detected position) is available.

Example and non-limiting plant position values 3614 include the robotposition information 3604 integrated within a definition of the plantspace, such as the inspection surface, a defined map of a portion of theplant or industrial system, and/or the plant position definition 3606.In certain embodiments, the plant space is predetermined, for example asa map interpreted by the controller 802 and/or pre-loaded in a data filedescribing the space of the plant, inspection surface, and/or a portionof the plant or industrial surface. In certain embodiments, the plantposition definition 3606 is created in real-time by the positiondefinition circuit 3602—for example by integrating the positioninformation 3604 traversed by the inspection robot, and/or by creating avirtual space that includes the position information 3604 traversed bythe inspection robot. For example, the position definition circuit 3602may map out the position information 3604 over time, and create theplant position definition 3606 as the aggregate of the positioninformation 3604, and/or create a virtual surface encompassing theaggregated plant position values 3614 onto the surface. In certainembodiments, the position definition circuit 3602 accepts a plant shapevalue 3608 as an input (e.g., a cylindrical tank being inspected by theinspection robot having known dimensions), deduces the plant shape value3608 from the aggregated position information 3604 (e.g., selecting fromone of a number of simple or available shapes that are consistent withthe aggregated plant position definition 3606), and/or prompts a user(e.g., an inspection operator and/or a client for the data) to selectone of a number of available shapes to determine the plant positiondefinition 3606.

The example apparatus 3600 includes a data positioning circuit 3610 thatinterprets inspection data 3612 and correlates the inspection data 3612to the position information 3604 and/or to the plant position values3614. Example and non-limiting inspection data 3612 includes: senseddata by an inspection robot; environmental parameters such as ambienttemperature, pressure, time-of-day, availability and/or strength ofwireless communications, humidity, etc.; image data, sound data, and/orvideo data taken during inspection operations; metadata such as aninspection number, customer number, operator name, etc.; setupparameters such as the spacing and positioning of sleds, payloads,mounting configuration of sensors, and the like; calibration values forsensors and sensor processing; and/or operational parameters such asfluid flow rates, voltages, pivot positions for the payload and/orsleds, inspection robot speed values, downforce parameters, etc. Incertain embodiments, the data positioning circuit 3610 determines thepositional information 3604 corresponding to inspection data 3612values, and includes the positional information 3604 as an additionalparameter with the inspection data 3612 values and/or stores acorrespondence table or other data structure to relate the positionalinformation 3604 to the inspection data 3612 values. In certainembodiments, the data positioning circuit 3610 additionally oralternatively determines the plant position definition 3606, andincludes a plant position value 3614 (e.g., as a position within theplant as defined by the plant position definition 3606) as an additionalparameter with the inspection data 3612 values and/or stores acorrespondence table or other data structure to relate the plantposition values 3614 to the inspection data 3612 values. In certainembodiments, the data positioning circuit 3610 creates position informeddata 3616, including one or more, or all, aspects of the inspection data3612 correlated to the position information 3604 and/or to the plantposition values 3614.

In certain embodiments, for example where dead reckoning operations areutilized to provide position information 3604 over a period of time, andthen a corrected position is available through a feedback positionmeasurement, the data positioning circuit 3602 updates the positioninformed inspection data 3616—for example re-scaling the data accordingto the estimated position for values according to the changed feedbackposition (e.g., where the feedback position measurement indicates theinspection robot traveled 25% further than expected by dead reckoning,position information 3604 during the dead reckoning period can beextended by 25%) and/or according to rationalization determinations orexternally available data (e.g., where over 60 seconds the inspectionrobot traverses 16% less distance than expected, but sensor readings orother information indicate the inspection robot may have been stuck for10 seconds, then the position information 3604 may be corrected torepresent the 10-seconds of non-motion rather than a full re-scale ofthe position informed inspection data 3616). In certain embodiments,dead reckoning operations may be corrected based on feedbackmeasurements as available, and/or in response to the feedbackmeasurement indicating that the dead reckoning position informationexceeds a threshold error value (e.g., 1%, 0.1%, 0.01%, etc.).

It can be seen that the operations of apparatus 3600 provide forposition-based inspection information. Certain systems, apparatuses, andprocedures throughout the present disclosure utilize and/or can benefitfrom position informed inspection data 3616, and all such embodimentsare contemplated herein. Without limitation to any other disclosuresherein, certain aspects of the present disclosure include: providing avisualization of inspection data 3612 in position information 3604 spaceand/or in plant position value 3614 space; utilizing the positioninformed inspection data 3616 in planning for a future inspection on thesame or a similar plant, industrial system, and/or inspection surface(e.g., configuring sled number and spacing, inspection robot speed,inspection robot downforce for sleds and/or sensors, sensorcalibrations, planning for traversal and/or avoidance of obstacles,etc.); providing a format for storing a virtual mark (e.g., replacing apaint or other mark with a virtual mark as a parameter in the inspectiondata 3612 correlated to a position); determining a change in a plantcondition in response to the position informed inspection data 3616(e.g., providing an indication that expected position information 3604did not occur in accordance with the plant position definition 3606—forexample indicating a failure, degradation, or unexpected object in aportion of the inspected plant that is not readily visible); and/orproviding a health indicator of the inspection surface (e.g., depictingregions that are nominal, passed, need repair, will need repair, and/orhave failed). In certain embodiments, it can be seen that constructingthe position informed inspection data 3616 using position information3604 only, including dead reckoning based position information 3604,nevertheless yields many of the benefits of providing the positioninformed inspection data 3616. In certain further embodiments, theposition informed inspection data 3616 is additionally or alternativelyconstructed utilizing the plant position definition 3606, and/or theplant position values 3614.

Referencing FIG. 15, an example procedure 3700 to inspect a plant,industrial system, and/or inspection surface utilizing positioninformation is depicted. The example procedure 3700 includes anoperation 3702 to interpret position information, an operation 3704 tointerpret inspection data, and an operation 3706 correlate theinspection data to the position information. The example procedure 3700further includes an operation 3708 to correct the position information(e.g., updating a dead reckoning-based position information), and toupdate the correlation of the inspection data to the positioninformation. The example procedure further includes an operation 3710 toprovide position informed inspection data in response to the correlatedinspection data. In certain embodiments, operation 3706 is additionallyor alternatively performed on the position informed inspection data,where the position informed inspection data is corrected, and operation3710 includes providing the position informed inspection data. Incertain embodiments, one or more operations of a procedure 3700 areperformed by a controller 802.

Referencing FIG. 16, an example procedure 3800 to inspect a plant,industrial system, and/or inspection surface utilizing positioninformation is depicted. In addition to operations of procedure 3700,example procedure 3800 includes an operation 3802 to determine a plantdefinition value, and an operation 3804 to determine plant positionvalues in response to the position information and the plant positiondefinition. Operation 3706 further includes an operation to correlatethe inspection data with the position information and/or the plantposition values. In certain embodiments, one or more operations ofprocedure 3800 are performed by a controller 802.

One or more certain further aspects of the example method may beincorporated in certain embodiments. The personnel risk feature mayinclude a portion of the inspection surface having an elevated height.The elevated height may include at least one height value consisting ofthe height values selected from: at least 10 feet, at least 20 feet, atleast 30 feet, greater than 50 feet, greater than 100 feet, and up to150 feet. The personnel risk feature may include an elevated temperatureof at least a portion of the inspection surface. The personnel riskfeature may include an enclosed space, and wherein at least a portion ofthe inspection surface is positioned within the enclosed space. Thepersonnel risk feature may include an electrical power connection.Determining a position of the inspection robot within the industrialsystem during the operating the inspection robot, and shutting down onlya portion of the industrial system during the inspection operation inresponse to the position of the inspection robot.

As shown in FIG. 17, a system may comprise a base station 4902 connectedby a tether 4904 to a housing or center module 4910 of a robot 4908 usedto traverse an industrial surface. The tether 4904 may be a conduit forpower, fluids, control, and data communications between the base station4902 and the robot 4908. The robot 4908 may include a center module 4910connected to one or more drive modules 4912 which enable the robot 4908to move along an industrial surface. The center module 4910 may becoupled to one or more sensor modules 4914 for measuring an industrialsurface—for example the sensor modules 4914 may be positioned on a drivemodule 4912, on the payload, in the center body housing, and/or aspectsof a sensor module 4914 may be distributed among these. An exampleembodiment includes the sensor modules 4914 each positioned on anassociated drive module 4912, and electrically coupled to the centermodule 4910 for power, communications, and and/or control. The basestation 4902 may include an auxiliary pump 4920, a control module 4924and a power module 4922. The example robot 4908 may be an inspectionrobot, which may include any one or more of the following features:inspection sensors, cleaning tools, and/or repair tools. In certainembodiments, it will be understood that an inspection robot 4908 isconfigured to perform only cleaning and/or repair operations, and/or maybe configured for sensing, inspection, cleaning, and/or repairoperations at different operating times (e.g., performing one type ofoperation at a first operating time, and performing another type ofoperation at a second operating time), and/or may be configured toperform more than one of these operations in a single run or traversalof an industrial surface (e.g., the “inspection surface”). The modules4910, 4912, 4914, 4920, 4922, 4924 are configured to functionallyexecute operations described throughout the present disclosure, and mayinclude any one or more hardware aspects as described herein, such assensors, actuators, circuits, drive wheels, motors, housings, payloadconfigurations, and the like.

The control module 4924 may be in communication with the robot 4908 byway of the tether 4904. Additionally or alternatively, the controlmodule 4924 may communicate with the robot 4908 wirelessly, through anetwork, or in any other manner. The robot 4908 may provide the basestation 4902 with any available information, such as, withoutlimitation: the status of the robot 4908 and associated components, datacollected by the sensor module 4914 regarding the industrial surface,vertical height of the robot 4908, water pressure and/or flow ratecoming into the robot 4908, visual data regarding the robot'senvironment, position information for the robot 4908 and/or information(e.g., encoder traversal distances) from which the control module 4924can determine the position of the robot. The control module 4924 mayprovide the robot 4908 with commands such as navigational commands,commands to the sensor modules regarding control of the sensor modulesand the like, warning of an upcoming power loss, couplant pressureinformation, and the like.

The base station 4902 may receive an input of couplant, typically water,from an external source such as a plant or municipal water source. Thebase station 4902 may include a pressure and/or flow sensing device tomeasure incoming flow rate and/or pressure. Typically, the incomingcouplant may be supplied directly to the tether 4904 for transport tothe robot 4908. However, if the incoming pressure is low or the flowrate is insufficient, the couplant may be run through the auxiliary pump4920 prior to supplying the couplant to the tether 4904. In certainembodiments, the base station 4902 may include a make-up tank and/or acouplant source tank, for example to supply couplant if an externalsource is unavailable or is insufficient for an extended period. Theauxiliary pump 4920 may be regulated by the control module 4924 based ondata from the sensor and/or combined with data received from the robot4908. The auxiliary pump 4920 may be used to: adjust the pressure of thecouplant sent to the robot 4908 based on the vertical height of therobot 4908; adjust for spikes or drops in the incoming couplant; provideintermittent pressure increases to flush out bubbles in the acousticpath of ultra-sonic sensors, and the like. The auxiliary pump 4920 mayinclude a shut off safety valve in case the pressure exceeds athreshold.

As shown in FIG. 18, the center module 4910 (or center body) of therobot may include a chassis couplant interface 5102, a datacommunications/control tether input 5112, forward facing and reversefacing navigation cameras 5104, multiple sensor connectors 5118,couplant outlets 5108 (e.g., to each payload), and one or more drivemodule connections 5110 (e.g., one on each side). An example centermodule 4910 includes a distributed controller design, with low-level andhardware control decision making pushed down to various low levelcontrol modules (e.g., 5114, and/or further control modules on the drivemodules as described throughout the present disclosure). The utilizationof a distributed controller design facilitates rapid design, rapidupgrades to components, and compatibility with a range of components andassociated control modules 5114. For example, the distributed controllerdesign allows the high level controller (e.g., the brain/gateway) toprovide communications in a standardized high-level format (e.g.,requesting movement rates, sensed parameter values, powering ofcomponents, etc.) without utilizing the hardware specific low-levelcontrols and interfaces for each component, allowing independentdevelopment of hardware components and associated controls. The use ofthe low-level control modules may improve development time and enablethe base level control module to be component neutral and send commands,leaving the specific implementation up to the low-level control module5114 associated with a specific camera, sensor, sensor module, actuator,drive module, and the like. The distributed controller design may extendto distributing the local control to the drive module(s) and sensormodule(s) as well.

Referring to FIGS. 19-20, the bottom surface of the center module 4910may include a cold plate 5202 to disperse heat built up by electronicsin the center module 4910. Couplant transferred from the base station4902 using the tether 4904 may be received at the chassis couplantinterface 5102 where it then flows through a manifold 5302 where thecouplant may transfer excess heat away from the central module 4910. Themanifold 5302 may also split the water into multiple streams for outputthrough two or more couplant outlets 5108. The utilization of the coldplate 5202 and heat transfer to couplant passing through the center bodyas a part of operations of the inspection robot provides for greatercapability and reliability of the inspection robot by providing forimproved heat rejection for heat generating components (e.g., powerelectronics and circuits), while adding minimal weight to the robot andtether. FIG. 19 depicts an example distribution of couplant flow throughthe cold plate and to each payload. In certain embodiments, couplantflow may also be provided to a rear payload, which may have a directflow passage and/or may further include an additional cold plate on arear portion of the inspection robot.

FIG. 24 shows an exterior and exploded view of a drive module 4912. Adrive module 4912 may include motors 5502 and motor shielding 5508, awheel actuator assembly 5504 housing the motor, and wheel assemblies5510 including, for example, a magnetic wheel according to any magneticwheel described throughout the present disclosure. An example drivemodule 4912 includes a handle 5512 to enable an operator to transportthe robot 4908 and position the robot 4908 on an industrial surface. Themotor shielding 5508 may be made of an electrically conductive material,and provide protection for the motors 5502 and associated motor positionand/or speed sensors (e.g., a hall effect sensor) from electro-magneticinterference (EMI) generated by the wheel assembly 5510. The drivemodule 4912 provides a mounting rail 5514 for a payload and/or sensormodule 4914, which may cooperate with a mounting rail on the center bodyto support the payload. An example drive module 4912 includes one ormore payload actuators 5518 (e.g., the payload gas spring) for engagingand disengaging the payload or sensor module 4914 from an inspectionsurface (or industrial surface), and/or for adjusting a down force ofthe payload (and thereby a downforce for specific sensor carriagesand/or sleds) relative to the inspection surface. The drive module 4912may include a connecter 5520 that provides an interface with the centermodule for power and communications.

FIGS. 21-22 depicts an external view of an example drive module 5402,5404, with an encoder assembly 5524 (reference FIG. 23) depicted in anextended position (FIG. 21) or a partially retracted position (FIG. 22).The encoder assembly 5524 in the examples of FIGS. 21-23 includes apassive wheel that remains in contact with the inspection surface, andan encoder detecting the turning of the wheel (e.g., including a halleffect sensor). The encoder assembly 5524 provides for an independentdetermination of the movement of the inspection robot, thereby allowingfor corrections, for example, where the magnetic wheels may slip or losecontact with the inspection surface, and accordingly the determinationof the inspection robot position and/or movement from the magneticwheels may not provide an accurate representation of the movement of theinspection robot. In certain embodiments, a drive module on each side ofthe center body each include a separate encoder assembly 5524, therebyproviding for detection and control for turning or other movement of theinspection robot.

Referring to FIG. 23, each drive module 5402 may have an embeddedmicrocontroller 5522 which provides control and communications relatingto the motors, actuators, sensors, and/or encoders associated with thatdrive module 5402. The embedded microcontroller 5522 responds tonavigational and/or speed commands from the base station 4902 and/orhigh level center body controller, obstacle detection, error detection,and the like. In certain embodiments, the drive module 5402 isreversible and will function appropriately, independent of the side ofthe center module 4910 to which it is attached. The drive module 5402may have hollowed out portions (e.g., the frame visible in FIG. 18)which may be covered, at least in part, of a screen (e.g., a carbonfiber screen) to reduce the overall weight of the drive module. Theutilization of a screen, in certain embodiments, provides protectionfrom the hollowed out portion filling with debris or other material thatmay provide increased weight and/or undesirable operation of theinspection robot.

FIG. 24 shows an exploded view of a wheel actuator assembly 5504 thatdrives a wheel assembly 5510 of the drive module 5402. A motor 5502 maybe attached to an aft plate 5604 with the motor shaft 5606 protrudingthrough the aft plate 5604. A wave generator 5608, a non-circular ballbearing, may be mounted to the motor shaft 5606. The wave generator 5608is spun inside of a cup style strain wave gearbox (flex spline cup5610). The flex spline cup 5610 may spin on the wave generator 5608 andinteract with a ring gear 5612, the ring gear 5612, having fewer teeththan the flex spline cup 5610. This causes the gear set to “walk” whichprovides for a high ratio of angular speed reduction in a compact form(e.g., a short axial distance). The flex spline cup 5610 may be bolted,using the bolt plate 5614 to the driveshaft output shaft 5618. Theinteraction of the wave generator 5608 and the flex spline cup 5610result in, for example, a fifty to one (50:1) reduction in rotationalspeed between the motor shaft 5606 and the driveshaft output shaft 5618.The example reduction ratio is non-limiting, and any desired reductionratio may be utilized. Example and non-limiting considerations for thereduction ratio include: the speed and/or torque profile of availablemotors 5502; the weight, desired trajectory (e.g., vertical, horizontal,or mixed), and/or desired speed of the inspection robot; the availablespace within the inspection robot for gear ratio management; the size(e.g. diameter) of the drive wheels, drive shaft, and/or any otheraspect of the driveline (e.g., torque path between the motor 5502 andthe drive wheels); and/or the available power to be provided to theinspection robot. Further, the use of this mechanical method ofreduction in rotational speed is not affected by any EMI produced by themagnets in the wheel modules (e.g., as a planetary gear set, or othergear arrangements might be).

In addition to providing power to drive a wheel assembly, a motor 5502may act as a braking mechanism for the wheel assembly. The board withthe embedded microcontroller 5522 for the motor 5502 may include a pairof power-off relays. When power to the drive module 5402 is lost orturned off, the power-off relays may short the three motor phases of themotor 5502 together, thus increasing the internal resistance of themotor 5502. The increased resistance of the motor 5502 may be magnifiedby the flex spline cup 5610, preventing the inspection robot 100 fromrolling down a wall in the event of a power loss.

There may be a variety of wheel assembly 5510 configurations, which maybe provided in alternate embodiments, swapped by changing out thewheels, and/or swapped by changing out the drive modules 5402.

Referring to FIGS. 25-28A stability module, also referred to as awheelie bar, may provide additional stability to a robot when the robotis moving vertically up an industrial surface. The wheelie bar 6000 maybe mounted at the back (relative to an upward direction of travel) of adrive module or to both ends of a drive module. If the front wheel of adrive module encounters a nonferrous portion of the industrial surfaceor a large obstacle is encountered, the wheelie bar 6000 limits theability of the robot to move away from the industrial surface beyond acertain angle, thus limiting the possibility of a backward roll-over bythe robot. The wheelie bar 6000 may be designed to be easily attachedand removed from the drive module connection points 6011. The strengthof magnets in the drive wheels may be such that each wheel is capable ofsupporting the weight of the robot even if the other wheels lost contactwith the surface. The wheels on the stability module may be magnetichelping the stability bar engage or “snap” into place when pushed intoplace by the actuator.

A stability module 6000 may attach to a drive module 5402 such that itis pulled behind or below the robot. FIG. 25 shows an exploded view of astability module 6000 which may include a pair of wheels 6004, astability body 6002, a connection bolt 6008 and two drive moduleconnection points 6010, an actuator pin 6012, and two actuatorconnection points 6014. An actuator may couple with one of the actuatorconnection points 6014, and/or a given embodiment may have a pair ofactuators, with one coupled to each actuator connection point 6014.There may be two drive module connection points 6010 which may bequickly aligned with corresponding stability module connection points6011 located adjacent to each wheel module on the drive module and heldtogether with the connection bolt 6008. The drive module may include agas spring 6020, which may be common with the payload gas spring 6020(e.g., providing for ease of reversibility of the drive module 4912 oneither side of the inspection robot), although the gas spring 6020 forthe stability module may have different characteristics and/or be adistinct actuator relative to the payload gas spring. The examplestability module includes a connection pin 6012 for rapid couplingand/or decoupling of the gas spring. The stability module may beattached, using stability module connection points, adjoining either ofthe wheel modules of the drive module. In certain embodiments, astability module 6000 may be coupled to the rear position of the drivemodules to assemble the inspection robot, and/or a stability module 6000may be provided in both the front and back of the inspection robot(e.g., using separate and/or additional actuators from the payloadactuators).

The strength of magnets in the drive wheels may be such that each wheelis capable of supporting the weight of the robot even if the otherwheels lose contact with the surface. In certain embodiments, the wheelson the stability module may be magnetic, helping the stability moduleengage or “snap” into place upon receiving downward pressure from thegas spring or actuator. In certain embodiments, the stability modulelimits the rearward rotation of the inspection robot, for example if thefront wheels of the inspection robot encounter a non-magnetic or dirtysurface and lose contact. In certain embodiments, the stability module6000 can return the front wheels to the inspection surface (e.g., byactuating and rotating the front of the inspection robot again towardthe surface, which may be combined with backing the inspection robotonto a location of the inspection surface where the front wheels willagain encounter a magnetic surface).

FIG. 28 depicts an alternate stability module 6200 including a stabilitybody 6202 which does not have wheels but does have a similar connectionbolt 6208 and two drive module connection points, and a similar actuatorpin and two actuator connection points. Again, the stability module 6200may have two drive module connection points 6010 which may be quicklyaligned with corresponding stability module connection points 6011located adjacent to each wheel module on the drive module and heldtogether with the connection bolt 6208. The drive module may include apayload gas spring 6220 which may be connected to the stability module6200 at one of two spring connection points with an actuator pin. Theoperations of stability module 6200 may otherwise be similar to theoperations of the wheeled stability module 6000.

FIGS. 29-31 depict details of the suspension between the center body anda drive module. The center module 4910 may include a piston 6304 toenable adjustments to the distance between the center module 4910 and adrive module 4912 to accommodate the topography of a given industrialsurface and facilitate the stability and maneuverability of the robot.The piston may be bolted to the drive module such that the piston doesnot rotate relative to the drive module. Within the piston, andprotected by the piston from the elements, there may be a power andcommunication center module connector 5520 to which a drive moduleconnector 5520 engages to provide for the transfer of power and databetween the center module and a drive module.

The suspension may include a translation limiter 6302 that limits thetranslated positions of the piston, a rotation limiter 6306 which limitshow far the center module may rotate relative to the drive module (seeexamples in FIGS. 30-31), and replaceable wear rings to reduce wear onthe piston 6304 and the center module 4910 as they move relative to oneanother. The drive module may be spring biased to a central, norotation, position, and/or may be biased to any other selected position(e.g., rotated at a selected angle). An example drive module-center bodycoupling includes a passive rotation that occurs as a result ofvariations in the surface being traversed.

The robot may have information regarding absolute and relative position.The drive module may include both contact and non-contact encoders toprovide estimates of the distance travelled. In certain embodiments,absolute position may be provided through integration of variousdeterminations, such as the ambient pressure and/or temperature in theregion of the inspection robot, communications with positional elements(e.g., triangulation and/or GPS determination with routers or otheravailable navigation elements), coordinated evaluation of the drivenwheel encoders (which may slip) with the non-slip encoder assembly,and/or by any other operations described throughout the presentdisclosure. In certain embodiments, an absolute position may be absolutein one sense (e.g., distance traversed from a beginning location or homeposition) but relative in another sense (e.g., relative to thatbeginning location).

There may be one or two encoder wheels positioned between the drivewheels, either side by side or in a linear orientation, and in certainembodiments a sensor may be associated with only one, or with both,encoder wheels. In certain embodiments, each of the drive modules 4912may have a separate encoder assembly associated therewith, providing forthe capability to determine rotational angles (e.g., as a failurecondition where linear motion is expected, and/or to enabletwo-dimensional traversal on a surface such as a tank or pipe interior),differential slip between drive modules 4912, and the like.

A drive module (FIG. 23) may include a hall effect sensor in each of themotors 5502 as part of non-contact encoder for measuring the rotation ofeach motor as it drives the associated wheel assembly 5510. There may beshielding 5508 (e.g., a conductive material such as steel) to preventunintended EMI noise from a magnet in the wheel inducing false readingsin the hall effect sensor.

Data from the encoder assembly 5524 encoder and the driven wheel encoder(e.g., the motion and/or position sensor associated with the drive motorfor the magnetic wheels) provide an example basis for derivingadditional information, such as whether a wheel is slipping by comparingthe encoder assembly readings (which should reliably show movement onlywhen actual movement is occurring) to those of the driven wheel encoderson the same drive module. If the encoder assembly shows limited or nomotion while the driven wheel encoder(s) show motion, drive wheelsslipping may be indicated. Data from the encoder assembly and the drivenwheel encoders may provide a basis for deriving additional informationsuch as whether the robot is travelling in a straight line, as indicatedby similar encoder values between corresponding encoders in each of thetwo drive modules on either side of the robot. If the encoders on one ofthe drive modules indicate little or no motion while the encoders of theother drive module show motion, a turning of the inspection robot towardthe side with limited movement may be indicated.

The base station may include a GPS module or other facility forrecognizing the position of the base station in a plant. The encoders onthe drive module provide both absolute (relative to the robot) andrelative information regarding movement of the robot over time. Thecombination of data regarding an absolute position of the base stationand the relative movement of the robot may be used to ensure completeplant inspection and the ability to correlate location with inspectionmap.

The central module may have a camera 5104 that may be used fornavigation and obstacle detection, and/or may include both a front andrear camera 5104 (e.g., as shown in FIG. 18). A video feed from aforward facing camera (relative to the direction of travel) may becommunicated to the base station to assist an operator in obstacleidentification, navigation, and the like. The video feed may switchbetween cameras with a change in direction, and/or an operator may beable to selectively switch between the two camera feeds. Additionally oralternatively, both cameras may be utilized at the same time (e.g.,provided to separate screens, and/or saved for later retrieval). Thevideo and the sensor readings may be synchronized such that, forexample: an operator (or display utility) reviewing the data would beable to have (or provide) a coordinated visual of the inspection surfacein addition to the sensor measurements to assist in evaluating the data;to provide repairs, mark repair locations, and/or confirm repairs;and/or to provide cleaning operations and/or confirm cleaningoperations. The video camera feeds may also be used for obstacledetection and path planning, and/or coordinated with the encoder data,other position data, and/or motor torque data for obstacle detection,path planning, and/or obstacle clearance operations.

Referring to FIG. 32, a drive module (and/or the center body) mayinclude one or more payload mount assemblies 6900. The payload mountassembly 6900 may include a rail mounting block 6902 with a wearresistant sleeve 6904 and a rail actuator connector 6912. Once a rail ofthe payload is slid into position, a dovetail clamping block 6906 may bescrewed down with a thumbscrew 6910 to hold the rail in place with acam-lock clamping handle 6908. The wear resistant sleeve 6904 may bemade of Polyoxymethylene (POM), a low friction, strong, high stiffnessmaterial such as Delrin, Celecon, Ramtal, Duracon, and the like. Thewear resistant sleeve 6904 allows the sensor to easily slide laterallywithin the rail mounting block 6902. The geometry of the dovetailclamping block 6906 limits lateral movement of the rail once it isclamped in place. However, when unclamped, it is easy to slide the railoff to change the rail. In another embodiment, the rail mounting blockmay allow for open jawed, full rail coupling allowing the rail to berapidly attached and detached without the need for sliding intoposition.

Referring to FIG. 33, an example of a rail 7000 is seen with a pluralityof sensor carriages 7004 attached and an inspection camera 7002attached. As shown in FIGS. 34-36, the inspection camera 7002 may beaimed downward (e.g., at 38 degrees) such that it captures an image ofthe inspection surface that can be coordinated with sensor measurements.The inspection video captured may be synchronized with the sensor dataand/or with the video captured by the navigation cameras on the centermodule. The inspection camera 7002 may have a wide field of view suchthat the image captured spans the width of the payload and the surfacemeasured by all of the sensor carriages 7004 on the rail 7000.

The length of the rail may be designed to according to the width ofsensor coverage to be provided in a single pass of the inspection robot,the size and number of sensor carriages, the total weight limit of theinspection robot, the communication capability of the inspection robotwith the base station (or other communicated device), the deliverabilityof couplant to the inspection robot, the physical constraints (weight,deflection, etc.) of the rail and/or the clamping block, and/or anyother relevant criteria. Referring to FIGS. 37-39, a rail may includeone or more sensor carriage clamps 7200 having joints with severaldegrees of freedom for movement to allow the robot to continue even ifone or more sensor carriages encounter unsurmountable obstacles (e.g.,the entire payload can be raised, the sensor carriage can articulatevertically and raise over the obstacle, and/or the sensor carriage canrotate and traverse around the obstacle).

The rail actuator connector 6912 may be connected to a rail (payload)actuator 5518 (FIG. 24) which is able to provide a configurabledown-force on the rail 7000 and the attached sensor carriages 7004 toassure contact and/or desired engagement angle with the inspectionsurface. The payload actuator 5518 may facilitate engaging anddisengaging the rail 7000 (and associated sensor carriages 7004) fromthe inspection surface to facilitate obstacle avoidance, angletransitions, engagement angle, and the like. Rail actuators 5518 mayoperate independently of one another. Thus, rail engagement angle mayvary between drive modules on either side of the center module, betweenfront and back rails on the same drive module, and the like.

A sensor clamp 7200 may allow sensor carriages 7004 to be easily addedindividually to the rail (payload) 7000 without disturbing other sensorcarriages 7004. A simple sensor set screw 7202 tightens the sensor clampedges 7204 of the sensor clamp 7200 over the rail. In the example ofFIGS. 38-39, a sled carriage mount 7206 provides a rotational degree offreedom for movement.

FIG. 40 depicts a multi-sensor sled carriage 7004, 7300. The embodimentof FIG. 40 depicts multiple sleds arranged on a sled carriage, but anyfeatures of a sled, sled arm, and/or payload described throughout thepresent disclosure may otherwise be present in addition to, or asalternatives to, one or more features of the multi-sensor sled carriage7004, 7300. The multi-sensor sled carriage 7300 may include a multiplesled assembly, each sled 7302 having a sled spring 7304 at the front andback (relative to direction of travel) to enable the sled 7302 to tiltor move in and out to accommodate the contour of the inspection surface,traverse obstacles, and the like. The multi-sensor sled carriage 7300may include multiple power/data connectors 7306, one running to eachsensor sled 7302, to power the sensor and transfer acquired data back tothe robot. Depending on the sensor type, the multi-sensor sled carriage7300 may include multiple couplant lines 7308 providing couplant to eachsensor sled 7302 requiring couplant.

Referring to FIGS. 41-42, in a top perspective depiction, twomultiple-sensor sled assemblies 7400 of different widths are shown, asindicated by the width label 7402. A multiple sled assembly may includemultiple sleds 7302. Acoustic sleds may include a couplant port 7404 forreceiving couplant from the robot. Each sled may have a sensor opening7406 to accommodate a sensor and engage a power/data connector 7306. Amultiple-sensor sled assembly width may be selected to accommodate theinspection surface to be traversed such as pipe outer diameter,anticipated obstacle size, desired inspection resolution, a desirednumber of contact points (e.g., three contact points ensuringself-alignment of the sled carriage and sleds), and the like. As shownin FIG. 43, an edge-on depiction of a multiple-sensor sled assembly, thesled spring 7304 may allow independent radial movement of each sled toself-align with the inspection surface. The rotational spacing 7502(tracing a circumference on an arc) between sleds may be fixed or may beadjustable.

In embodiments, a sensor carriage may comprise a universal single sledsensor assembly 7800 as shown in FIG. 44. The universal single sledsensor assembly 7800 may include a single sensor housing 7802 havingsled springs 7804 at the front and back (relative to direction oftravel) to enable the sensor housing (sled) 7802 to tilt or move in andout to accommodate the contour of the inspection surface, traverseobstacles and the like. The universal single sled sensor assembly 7800may have a power/data connector 7806 to power the sensor and transferacquired data back to the robot. The universal single sled sensorassembly 7800 may include multiple couplant lines 7808 attached to amulti-port sled couplant distributor 7810. Unused couplant ports 7812may be connected to one another to simply reroute couplant back into acouplant system.

In embodiments, identification of a sensor and its location on a railand relative to the center module may be made in real-time during apre-processing/calibration process immediately prior to an inspectionrun, and/or during an inspection run (e.g., by stopping the inspectionrobot and performing a calibration). Identification may be based on asensor ID provided by an individual sensor, visual inspection by theoperator or by image processing of video feeds from navigation andinspection cameras, and user input include including specifying thelocation on the robot and where it is plugged in. In certainembodiments, identification may be automated, for example by poweringeach sensor separately and determining which sensor is providing asignal.

An example procedure for detecting and/or traversing obstacles isdescribed following. An example procedure includes evaluating at leastone of: a wheel slippage determination value, a motor torque value, anda visual inspection value (e.g., through the camera, by an operator orcontroller detecting an obstacle directly and/or verifying motion). Theexample procedure further includes determining that an obstacle ispresent in response to the determinations. In certain embodiments, oneor more determinations are utilized to determine that an obstacle may bepresent (e.g., a rapid and/or low-cost determination, such as the wheelslippage determination value and/or the motor torque value), and anotherdetermination is utilized to confirm the obstacle is present and/or toconfirm the location of the obstacle (e.g., the visual inspection valueand/or the wheel slippage determination value, which may be utilized toidentify the specific obstacle and/or confirm which side of theinspection robot has the obstacle). In certain embodiments, one or moreobstacle avoidance maneuvers may be performed, which may be scheduled inan order of cost, risk, and/or likelihood of success, including suchoperations as: raising the payload, facilitating a movement of thesensor carriage around the obstacle, reducing and/or manipulating a downforce of the payload and/or of a sensor carriage, moving the inspectionrobot around and/or to avoid the obstacle, and/or changing theinspection run trajectory of the inspection robot.

In an embodiment, and referring to FIG. 49, a payload 18400 for aninspection robot for inspecting an inspection surface may include apayload mount assembly 6900 couplable to a rail selectively coupled to achassis or the inspection robot or a drive module of the inspectionrobot, an arm 18408 having a first end 18410 and a second end 18412, thefirst end 18410 coupled to an arm mount 18406 of the payload; one ormore sleds 18414 mounted to the second end 18412 of the arm 18408; andat least two inspection sensors 18416, wherein each of the at least twoinspection sensors 18416 are mounted to a corresponding sled 18414 ofthe one or more sleds, and operationally couplable to the inspectionsurface; wherein the arm mount 18406 may be moveable in relation to thepayload mount assembly 6900. The arm mount 18406 may further include ahose guide 18424 to manage a coolant hose position.

The term selectively couplable (and similar terms) as utilized hereinshould be understood broadly. Without limitation to any other aspect ordescription of the present disclosure, selectively couplable describes aselected association between objects. For example, an interface ofobject 1 may be so configured as to couple with an interface of object 2but not with the interface of other objects. An example of selectivecoupling includes a power cord designed to couple to certain models of aparticular brand of computer, while not being able to couple with othermodels of the same brand of computer. In certain embodiments,selectively couplable includes coupling under selected circumstancesand/or operating conditions, and/or includes de-coupling under selectedcircumstances and/or operating conditions.

In an embodiment, the arm mount 18406 may be moveable in relation to thepayload mount assembly 6900. In an embodiment, the first end of the arm18408 may be moveable in relation to the arm mount 18406. In anembodiment, the first end 18410 of the arm 18408 may rotate in relationto the arm mount 18406 around pivot point 16. In an embodiment, thepayload mount assembly 6900 is rotatable with respect to a first axis,and wherein the first end of the arm is rotatable in a second axisdistinct from the first axis.

In an embodiment, the one or more sleds 18414 may be rotatable inrelation to the second end 18412 of the arm 18408 at joint 18422. Thepayload may further include at least two sleds 18414, and wherein the atleast two sleds 18414 may be rotatable as a group in relation to thesecond end 18412 of the arm 18408. The payload may further include adownward biasing force device 18418 structured to selectively apply adownward force to the at least two inspection sensors 18416 with respectto the inspection surface. In embodiments, the weight position of thedevice 18418 may be set at design time or run time. In some embodiments,weight positions may only include a first position or a second position,or positions in between (a few, a lot, or continuous). In embodiments,the downward biasing force device 18418 may be disposed on the secondportion 18406 of the payload mount assembly 6900. The downward biasingforce device 18418 may be one or more of a weight, a spring, anelectromagnet, a permanent magnet, or an actuator. The downward biasingforce device 18418 may include a weight moveable between a firstposition applying a first downward force and a second position applyinga second downward force. The downward biasing force device 18418 mayinclude a spring, and a biasing force adjustor moveable between a firstposition applying a first downward force and a second position applyinga second downward force. In embodiments, the force of the device 18418may be set at design time or run time. In embodiments, the force of thedevice 18418 may be available only at a first position/second position,or positions in between (a few, a lot, or continuous). For example,setting the force may involve compressing a spring or increasing atension, such as in a relevant direction based on spring type. Inanother example, setting the force may involve changing out a spring toone having different properties, such as at design time. In embodiments,the spring may include at least one of a torsion spring, a tensionspring, a compression spring, or a disc spring. The payload 18400 mayfurther include an inspection sensor position actuator, structured toadjust a position of the at least two inspection sensors 18416 withrespect to the inspection surface. The payload may further include atleast two sensors 18416, wherein the payload mount assembly 6900 may bemoveable with respect to the chassis of the inspection robot and theinspection sensor position actuator may be coupled to the chassis,wherein the inspection sensor position actuator in a first positionmoves the payload mount assembly 6900 to a corresponding first couplerposition, thereby moving the at least two sensors 18416 to acorresponding first sensor position, and wherein the inspection sensorposition actuator in a second position moves the payload mount assembly6900 to a corresponding second coupler position, thereby moving the atleast two sensors 18416 to a corresponding second sensor position. Insome embodiments, the inspection sensor position actuator may be coupledto a drive module. In some embodiments, a payload position may include adown force selection (e.g., actuator moves to touch sensors down,further movement may be applying force and may not correspond to fullymatching geometric movement of the payload coupler). In embodiments, theinspection sensor position actuator may be structured to rotate thepayload mount assembly 6900 between the first coupler position and thesecond coupler position. The actuator may be structured to horizontallytranslate the payload mount assembly 6900 between the first couplerposition and the second coupler position. The payload may furtherinclude a couplant conduit 10510 (FIG. 131) structured to fluidlycommunicate couplant between a chassis couplant interface 5102 (FIG. 18)and a payload couplant interface and wherein each of the at least twoinspection sensors 18416 may be fluidly coupled to the payload couplantinterface. In an embodiment, the couplant conduit 10510 may be from thechassis to the payload such that a single payload connection suppliesall related sensors.

The term fluidly communicate (and similar terms) as utilized hereinshould be understood broadly. Without limitation to any other aspect ordescription of the present disclosure, fluid communication describes amovement of a fluid, a gas or a liquid, between two points. In someexamples, the movement of the fluid between the two points can be one ofmultiple ways the two points are connected, or may be the only way theyare connected. For example, a device may supply air bubbles into aliquid in one instance, and in another instance the device may alsosupply electricity from a battery via the same device toelectrochemically activate the liquid.

The term universal conduit (and similar terms) as utilized herein shouldbe understood broadly. Without limitation to any other aspect ordescription of the present disclosure, a universal conduit describes aconduit capable of providing multiple other conduits or connectors, suchas fluid, electricity, communications, or the like. In certainembodiments, a universal conduit includes a conduit at least capable toprovide an electrical connection and a fluid connection. In certainembodiments, a universal conduit includes a conduit at least capable toprovide an electrical connection and a communication connection.

The term mechanically couple (and similar terms) as utilized hereinshould be understood broadly. Without limitation to any other aspect ordescription of the present disclosure, mechanically coupling describesconnecting objects using a mechanical interface, such as joints,fasteners, snap fit joints, hook and loop, zipper, screw, rivet, or thelike.

The example controller 802 is depicted schematically as a single devicefor clarity of description, but the controller 802 may be a singledevice, a distributed device, and/or may include portions at leastpartially positioned with other devices in the system (e.g., on theinspection robot 100). In certain embodiments, the controller 802 may beat least partially positioned on a computing device associated with anoperator of the inspection (not shown), such as a local computer at afacility including the inspection surface 500, a laptop, and/or a mobiledevice. In certain embodiments, the controller 802 may alternatively oradditionally be at least partially positioned on a computing device thatis remote to the inspection operations, such as on a web-based computingdevice, a cloud computing device, a communicatively coupled device, orthe like.

In an embodiment, and referring to FIG. 45, a system 10400 may includean inspection robot 10402 comprising a payload 10404; at least one arm10406, wherein each arm 10406 is pivotally mounted to a payload 10404;at least two sleds 10408, wherein each sled 10408 is mounted to the atleast one arm 10406; a plurality of inspection sensors 10410, each ofthe inspection sensors 10410 coupled to one of the sleds 10408 such thateach sensor is operationally couplable to an inspection surface 10412,wherein the at least one arm is horizontally moveable relative to acorresponding payload 10404; and a tether 10502 including an electricalpower conduit 10506 operative to provide electrical power; and a workingfluid conduit 10504 operative to provide a working fluid. In anembodiment, the working fluid may be a couplant and the working fluidconduit 10504 may be structured to fluidly communicate with at least onesled 10408 to provide for couplant communication via the couplantbetween an inspection sensor 10410 mounted to the at least one sled10408 and the inspection surface 10412. In an embodiment, the couplantprovides acoustic communication between the inspection sensor and theinspection surface. In an embodiment, the couplant does not perform work(W). In an embodiment, the working fluid conduit 10504 has an innerdiameter 10512 of about one eighth of an inch. In an embodiment, thetether 10502 may have an approximate length selected from a listconsisting of: 4 feet, 6 feet, 10 feet, 15 feet, 24 feet, 30 feet, 34feet, 100 feet, 150 feet, 200 feet, or longer than 200 feet. In anembodiment, the working fluid may be at least one of: a paint; acleaning solution; and a repair solution. In certain embodiments, theworking fluid additionally or alternatively is utilized to coolelectronic components of the inspection robot, for example by beingpassed through a cooling plate in thermal communication with theelectronic components to be cooled. In certain embodiments, the workingfluid is utilized as a cooling fluid in addition to performing otherfunctions for the inspection robot (e.g., utilized as a couplant forsensors). In certain embodiments, a portion of the working fluid may berecycled to the base station and/or purged (e.g., released from theinspection robot and/or payload), allowing for a greater flow rate ofthe cooling fluid through the cooling plate than is required for otherfunctions in the system such as providing sensor coupling.

It should be understood that any operational fluid of the inspectionrobot 10402 may be a working fluid. The tether 10502 may further includea couplant conduit 10510 operative to provide a couplant. The system10400 may further include a base station 10418, wherein the tether 10502couples the inspection robot 10402 to the base station 10418. The tether10502 may couple to a central chassis 10414 of the inspection robot10402. In an embodiment, the base station 10418 may include a controller10430; and a lower power output electrically coupled to each of theelectrical power conduit 10506 and the controller 10430, wherein thecontroller 10430 may be structured to determine whether the inspectionrobot 10402 is connected to the tether 10502 in response to anelectrical output of the lower power output. In embodiments, theelectrical output may be at least 18 Volts DC. In an embodiment, thecontroller 10430 may be further structured to determine whether anovercurrent condition exists on the tether 10502 based on an electricaloutput of the lower power output. The tether 10502 may further include acommunication conduit 10508 operative to provide a communication link,wherein the communication conduit 10508 comprises an optical fiber or ametal wire. Since fiber is lighter than metal for communication lines,the tether 10502 can be longer for vertical climbs because it weighsless. A body of the tether 10502 may include at least one of: a strainrelief 10420; a heat resistant jacketing 10514; a wear resistant outerlayer 10516; and electromagnetic shielding 10518. In embodiments, thetether 10502 may include similar wear materials. In embodiments, thesizing of the conduits 10504, 10506, 10508, 10510 may be based on powerrequirements, couplant flow rate, recycle flow rate, or the like.

In an embodiment, and referring to FIGS. 45 and 131, a tether 10502 forconnecting an inspection robot 10402 to a base station 10418 may includean electrical power conduit 10506 comprising an electrically conductivematerial; a working fluid conduit 10504 defining a working fluid passagetherethrough; a base station interface 10432 positioned at a first endof the tether 10502, the base station interface operable to couple thetether 10502 to a base station 10418; a robot interface 10434 positionedat a second end of the tether, the robot interface operable to couplethe tether 10502 to the inspection robot 10402; a strain relief 10420; awear resistance outer layer 10516; and electromagnetic shielding 10518.The tether may further include a communication conduit 10508, whereinthe communication conduit 10508 may include an optical fiber or a metalwire. The electrical power conduit 10506 may further include acommunications conduit 10508. In an embodiment, the working fluidconduit 10504 may have an inner diameter 10512 of about one eighth of aninch.

Operations of the inspection robot 100 provide the sensors 2202 inproximity to selected locations of the inspection surface 500 andcollect associated data, thereby interrogating the inspection surface500. Interrogating, as utilized herein, includes any operations tocollect data associated with a given sensor, to perform data collectionassociated with a given sensor (e.g., commanding sensors, receiving datavalues from the sensors, or the like), and/or to determine data inresponse to information provided by a sensor (e.g., determining values,based on a model, from sensor data; converting sensor data to a valuebased on a calibration of the sensor reading to the corresponding data;and/or combining data from one or more sensors or other information todetermine a value of interest). A sensor 2202 may be any type of sensoras set forth throughout the present disclosure, but includes at least aUT sensor, an EMI sensor (e.g., magnetic induction or the like), atemperature sensor, a pressure sensor, an optical sensor (e.g.,infrared, visual spectrum, and/or ultra-violet), a visual sensor (e.g.,a camera, pixel grid, or the like), or combinations of these.

Referencing FIG. 46, an example stability module assembly 13714 isdepicted. The example stability module assembly is couplable to a drivemodule and/or a center chassis of an inspection robot, and is positionedat a rear of the inspection robot to assist in ensuring the robot doesnot rotate backwards away from the inspection surface (e.g., uponhitting an obstacle, debris, encountering a non-ferrous portion of theinspection surface with front drive wheels, etc.). The example includesa coupling interface 13710, 13706 of any type, depicted as axles ofengaging matching holes defined in the stability module assembly 13714and the coupled device 13720 (e.g., a drive module, chassis, etc.). Theexample coupling arrangement utilizes a pin 13708 to secure theconnection. The example stability module assembly 13714 includes anengaging member 13704 for the inspection surface, which may include oneor more wheels, and/or a drag bar. In certain embodiments, the engagingmember 13704 is nominally positioned to contact the inspection surfacethroughout inspection operations, but may additionally or alternativelybe positioned to engage the inspection surface in response to theinspection robot rotating away from the inspection surface by a selectedamount. The example stability module assembly 13714 includes a biasingmember 13716, for example a spring, that opposes further rotation of theinspection robot when the stability module assembly 13714 engages theinspection surface. The biasing member 13716 in the example is engagedat a pivot axle 13718 of the stability module assembly 13714, and withinan enclosure 13712 or upper portion. In certain embodiments, the upperportion 13712 (or upper stability body) and lower portion 13702 (orlower stability body) are rotationally connected, where the biasingmember opposes rotation of the upper portion 13712 toward the lowerportion 13702.

Referencing again FIGS. 27-29, examples of stability module assembly13714 arrangements are depicted. In certain embodiments, the engagingmember may be a drag bar (e.g., FIG. 29). In certain embodiments, thestability module assembly 13714 may be coupled to an actuator 6020 atconnection point 6019 allowing for deployment of the stability moduleassembly, and/or for the application of selected down force by thestability module assembly to provide an urging force to the inspectionrobot to return front wheels and/or a payload to the inspection surface,and/or to adjust a down force applied by a payload, sensor, and/or sled.In certain embodiments, where a wheel of the stability module assembly13714 engages the inspection surface, an encoder may be operationallycoupled to the wheel, and may provide position information to the drivemodule and/or a controller of the inspection robot. In certainembodiments, the stability module assembly 13714 may move between astored position (e.g., rotated away from the inspection surface, and/orpositioned above the chassis and/or a drive module of the inspectionrobot). Without limitation to any other aspect of the presentdisclosure, FIG. 26 additionally depicts an example stability moduleassembly in an exploded view.

Operations of the inspection robot 100 provide the sensors 2202 inproximity to selected locations of the inspection surface 500 andcollect associated data, thereby interrogating the inspection surface500. Interrogating, as utilized herein, includes any operations tocollect data associated with a given sensor, to perform data collectionassociated with a given sensor (e.g., commanding sensors, receiving datavalues from the sensors, or the like), and/or to determine data inresponse to information provided by a sensor (e.g., determining values,based on a model, from sensor data; converting sensor data to a valuebased on a calibration of the sensor reading to the corresponding data;and/or combining data from one or more sensors or other information todetermine a value of interest). A sensor 2202 may be any type of sensoras set forth throughout the present disclosure, but includes at least aUT sensor, an EMI sensor (e.g., magnetic induction or the like), atemperature sensor, a pressure sensor, an optical sensor (e.g.,infrared, visual spectrum, and/or ultra-violet), a visual sensor (e.g.,a camera, pixel grid, or the like), or combinations of these.

Referencing FIG. 54, an example system is depicted, capable to performrapid configuration of an inspection robot in response to plannedinspection operations and/or an inspection request from a consumer ofthe inspection data and/or processed values and/or visualizationsdetermined from the inspection data.

The example system includes an inspection robot 20314. The inspectionrobot 20314 includes any inspection robot configured according to anyembodiment set forth throughout the present disclosure, including forexample, an inspection robot configured to interrogate an inspectionsurface using a number of input sensors. In certain embodiments, thesensors may be coupled to the inspection robot body 20312 (and/or centerchassis, chassis housing, central module, housing or similar componentsof the inspection robot) using one or more payloads. Each payload mayadditionally include components such as arms (e.g., to fix horizontalpositions of a sensor or group of sensors relative to the payload, toallow for freedom of movement pivotally, rotationally, or the like).Each arm, where present, or the payload directly, may be coupled to asled housing one or more of the input sensors. The inspection robot20314 may further include a tether providing for freedom of movementalong an inspection surface, while having supplied power, couplant,communications, or other aspects as described herein. The inspectionrobot 20314 and/or components thereof may include features to allow forquick changes to sleds or sled portions (e.g., a bottom contactsurface), to arms of a payload, and/or for entire payload changes (e.g.,from first payload having a first sensor group to a second payloadhaving a second sensor group, between payloads having pre-configured anddistinct sensor arrangements or horizontal spacing, between payloadshaving pre-configured arrangements for different types orcharacteristics of an inspection surface, etc.). The inspection robotmay include features allowing for rapid changing of payloads, forexample having a single interface for communications and/or couplantcompatible with multiple payloads, removable and/or switchable drivemodules allowing for rapid changing of wheel configurations, encoderconfigurations, motor power capabilities, stabilizing device changes,and/or actuator changes (e.g., for an actuator coupled to a payload toprovide for raising/lowering operations of the payload, selectable downforce applied to the payload, etc.). The inspection robot may furtherinclude a distribution of controllers and/or control modules within theinspection robot body, on drive modules, and/or associated with sensors,such that hardware changes can be implemented without changes requiredfor a high level inspection controller. The inspection robot may furtherinclude distribution of sensor processing or post-processing, forexample between the inspection controller or another controllerpositioned on the inspection robot, a base station computing device, anoperator computing device, and/or a non-local computing device (e.g., ona cloud server, a networked computing device, a base facility computingdevice where the base facility is associated with an operator for theinspection robot), or the like. Any one or more of the describedfeatures for the inspection robot 20314, without limitation to any otheraspect of the present disclosure, may be present and/or may be availablefor a particular inspection robot 20314. It can be seen that theembodiments of the present disclosure provide for multiple options toconfigure an inspection robot 20314 for the specific considerations of aparticular inspection surface and/or inspection operation of aninspection surface. The embodiments set forth in FIGS. 55-56, and otherembodiments set forth in the present disclosure, provide for rapidconfiguration of the inspection robot, and further provide for, incertain embodiments, responsiveness to inspection requirements and/orinspection requests, improved assurance that a configuration will becapable to perform a successful inspection operation includingcapability to retrieve the selected data and to successfully traversethe inspection surface.

The example inspection robot 20314 includes one or more hardwarecomponents 20304, 20308, which may be sensors and/or actuators of anytype as set forth throughout the present disclosure. The hardwarecomponents 20304, 20308 are depicted schematically as coupled to thecenter chassis 20312 of the inspection robot 20314, and may further bemounted on, or form part of a sled, arm, payload, drive module, or anyother aspect as set forth herein. The example inspection robot 20314includes hardware controller 20306, with one example hardware controllerpositioned on an associated component, and another example hardwarecontroller separated from the inspection controller 20310, andinterfacing with the hardware component and the inspection controller.

The example of FIG. 55 further includes a robot configuration controller20302. In the example, the robot configuration controller 20302 iscommunicatively coupled to the inspection robot 20314, a user interface20316, and/or an operator interface 20318. The example robotconfiguration controller 20302 is depicted separately for clarity of thepresent description, but may be included, in whole or part, on othercomponents of the system, such as the operator interface 20318 (and/oran operator associated computing device) and/or on the inspection robot20314. Communicative coupling between the robot configuration controller20302 and other components of the system may include a web basedcoupling, an internet based coupling, a LAN or WAN based coupling, amobile device coupling, or the like. In certain embodiments, one or moreaspects of the robot configuration controller 20302 are implemented as aweb portal, a web page, an application and/or an application with anAPI, a mobile application, a proprietary or dedicated application,and/or combinations of these.

In the example of FIG. 55, a user 20320 is depicted interacting with theuser interface 20316. The user interface 20316 may provide displayoutputs to the user 20320, such as inspection data, visualizations ofinspection data, refined inspection data, or the like. The userinterface 20316 may communicate user inputs to the robot configurationcontroller 20302 or other devices in the system. User inputs may beprovided as interactions with an application, touch screen inputs, mouseinputs, voice command inputs, keyboard inputs, or the like. The userinterface 20316 is depicted as a single device, but multiple userinterfaces 20316 may be present, including multiple user interfaces20316 for a single user (e.g., multiple physical devices such as alaptop, smart phone, desktop, terminal, etc.) and/or multiple back endinterfaces accessible to the user (e.g., a web portal, web page, mobileapplication, etc.). In certain embodiments, a given user interface 20316may be accessible to more than one user 20320.

In the example of FIG. 55, an operator 20322 is depicted interactingwith the operator interface 20318 and/or the inspection robot 20314. Aswith the user 20320 and the user interface 20316, more than one operator20322 and operator interface 20318 may be present, and further may bepresent in a many-to-many relationship. As utilized herein, and withoutlimitation to any other aspect of the present disclosure, the operator20322 participates in or interacts with inspection operations of theinspection robot 20314, and/or accesses the inspection robot 20314 toperform certain configuration operations, such as adding, removing, orswitching hardware components, hardware controllers, or the like.

An example system includes an inspection robot 20314 having aninspection controller 20310 that operates the inspection robot utilizinga first command set. The operations utilizing the first command set mayinclude high level operations, such as commanding sensors to interrogatethe inspection surface, commanding the inspection robot 20314 totraverse the surface (e.g., position progressions or routing, movementspeed, sensor sampling rates and/or inspection resolution/spacing on theinspection surface, etc.), and/or determining inspection stateconditions such as beginning, ending, sensing, etc.

The example system further includes a hardware component 20304, 20308operatively couplable to the inspection controller 20310, and a hardwarecontroller 20306 that interfaces with the inspection controller 20310 inresponse to the first command set, and commands the hardware component20304, 20308 in response to the first command set. For example, theinspection controller 20310 may provide a command such as a parameterinstructing a drive actuator to move, instructing a sensor to beginsensing operations, or the like, and the hardware controller 20306determines specific commands for the hardware component 20304, 20308 toperform operations consistent with the command from the inspectioncontroller 20310. In another example, the inspection controller 20310may request a data parameter (e.g., a wall thickness of the inspectionsurface), and the hardware controller interprets the hardware component20304, 20308 sensed values that are responsive to the requested dataparameter. In certain embodiments, the hardware controller 20306utilizes a response map for the hardware component 20304, 20308 tocontrol the component and/or understand data from the component, whichmay include A/D conversions, electrical signal ranges and/or reservedvalues, calibration data for sensors (e.g., return time assumptions,delay line data, electrical value to sensed value conversions,electrical value to actuator response conversions, etc.). It can be seenthat the example arrangement utilizing the inspection controller 20310and the hardware controller 20306 relieves the inspection controller20310 from relying upon low-level hardware interaction data, and allowsfor a change of a hardware component 20304, 20308, even at a giveninterface to the inspection controller 20310 (e.g., connected to aconnector pin, coupled to a payload, coupled to an arm, coupled to asled, coupled to a power supply, and/or coupled to a fluid line),without requiring a change in the inspection controller 20310.Accordingly, a designer, configuration operator, and/or inspectionoperator, considering operations performed by the inspection controller20310 and/or providing algorithms to the inspection controller 20310 canimplement and/or update those operations or algorithms without having toconsider the specific hardware components 20304, 20308 that will bepresent on a particular embodiment of the system. Embodiments describedherein provide for rapid development of operational capabilities,upgrades, bug fixing, component changes or upgrades, rapid prototyping,and the like by separating control functions.

The example system includes a robot configuration controller 20302 thatdetermines an inspection description value, determines an inspectionrobot configuration description in response to the inspectiondescription value, and provides at least a portion of the inspectionrobot configuration description to a configuration interface (not shown)of the inspection robot 20314, to the operator interface 20318, or both,and may provide a first portion (or all) of the inspection robotconfiguration description to the configuration interface, and a secondportion (or all) of the inspection robot configuration description tothe operator interface 20318. In certain embodiments, the first portionand the second portion may include some overlap, and/or the superset ofthe first portion and second portion may not include all aspects of theinspection robot configuration description. In certain embodiments, thesecond portion may include the entire inspection robot configurationdescription and/or a summary of portions of the inspection robotconfiguration description—for example to allow the operator (and/or oneor more of a number of operators) to save the configuration description(e.g., to be communicated with inspection data, and/or saved with theinspection data), and/or for verification (e.g., allowing an operator todetermine that a configuration of the inspection robot is properly made,even for one or more aspects that are not implemented by the verifyingoperator). Further details of operations of the robot configurationcontroller 20302 that may be present in certain embodiments are setforth elsewhere in the disclosure.

In certain embodiments, the hardware controller 20306 determines aresponse map for the hardware component 20304, 20308 in response to theprovided portion of the inspection robot configuration description.

In certain embodiments, the robot configuration controller 20302interprets a user inspection request value, for example from the userinterface 20316, and determines the inspection description value inresponse to the user inspection request value. For example, one or moreusers 20320 may provide inspection request values, such as an inspectiontype value (e.g., type of data to be taken, result types to be detectedsuch as wall thickness, coating conformity, damage types, etc.), aninspection resolution value (e.g., a distance between inspectionpositions on the inspection surface, a position map for inspectionpositions, a largest un-inspected distance allowable, etc.), aninspected condition value (e.g., pass/fail criteria, categories ofinformation to be labeled for the inspection surface, etc.), aninspection ancillary capability value (e.g., capability to repair, mark,and/or clean the surface, capability to provide a couplant flow rate,capability to manage a given temperature, capability to performoperations given a power source description, etc.), an inspectionconstraint value (e.g., a maximum time for the inspection, a definedtime range for the inspection, a distance between an available basestation location and the inspection surface, a couplant source amount ordelivery rate constraint, etc.), an inspection sensor distributiondescription (e.g., a horizontal distance between sensors, a maximumhorizontal extent corresponding to the inspection surface, etc.), anancillary component description (e.g., a component that should be madeavailable on the inspection robot, a description of a supportingcomponent such as a power connector type, a couplant connector type, afacility network description, etc.), an inspection surface verticalextent description (e.g., a height of one or more portions of theinspection surface), a couplant management component description (e.g.,a composition, temperature, pressure, etc. of a couplant supply to beutilized by the inspection robot during inspection operations), and/or abase station capability description (e.g., a size and/or positionavailable for a base station, coupling parameters for a power sourceand/or couplant source, relationship between a base station position andpower source and/or couplant source positions, network type and/oravailability, etc.).

Example and non-limiting user inspection request values include aninspection type value, an inspection resolution value, an inspectedcondition value, and/or an inspection constraint value. Example andnon-limiting inspection robot configuration description(s) include oneor more of an inspection sensor type description (e.g., sensed values;sensor capabilities such as range, sensing resolution, sampling rates,accuracy values, precision values, temperature compatibility, etc.;and/or a sensor model number, part number, or other identifyingdescription), an inspection sensor number description (e.g., a totalnumber of sensors, a number of sensors per payload, a number of sensorsper arm, a number of sensors per sled, etc.), an inspection sensordistribution description (e.g., horizontal distribution; verticaldistribution; spacing variations; and/or combinations of these withsensor type, such as a differential lead/trailing sensor type orcapability), an ancillary component description (e.g., a repaircomponent, marking component, and/or cleaning component, includingcapabilities and/or constraints applicable for the ancillary component),a couplant management component description (e.g., pressure and/orpressure rise capability, reservoir capability, compositioncompatibility, heat rejection capability, etc.), and/or a base stationcapability description (e.g., computing power capability, powerconversion capability, power storage and/or provision capability,network or other communication capability, etc.).

The term relative position (and similar terms) as utilized herein shouldbe understood broadly. Without limitation to any other aspect ordescription of the present disclosure, relative position includes anypoint defined with reference to another position, either fixed ormoving. The coordinates of such a point are usually bearing, true orrelative, and distance from an identified reference point. Theidentified reference point to determine relative position may includeanother component of the apparatus or an external component, a point ona map, a point in a coordinate system, or the like. The term relativeposition (and similar terms) as utilized herein should be understoodbroadly. Without limitation to any other aspect or description of thepresent disclosure, relative position includes any point defined withreference to another position, either fixed or moving. The coordinatesof such a point are usually bearing, true or relative, and distance froman identified reference point. The identified reference point todetermine relative position may include another component of theapparatus or an external component, a point on a map, a point in acoordinate system, or the like.

The example inspection robot 100 includes any inspection robot having anumber of sensors associated therewith and configured to inspect aselected area. Without limitation to any other aspect of the presentdisclosure, an inspection robot 100 as set forth throughout the presentdisclosure, including any features or characteristics thereof, iscontemplated for the example system depicted in. In certain embodiments,the inspection robot 100 may have one or more payloads 2 (FIG. 1) andmay include one or more sensors 2202 (FIG. 55) on each payload.

Operations of the inspection robot 100 provide the sensors 2202 inproximity to selected locations of the inspection surface 500 andcollect associated data, thereby interrogating the inspection surface500. Interrogating, as utilized herein, includes any operations tocollect data associated with a given sensor, to perform data collectionassociated with a given sensor (e.g., commanding sensors, receiving datavalues from the sensors, or the like), and/or to determine data inresponse to information provided by a sensor (e.g., determining values,based on a model, from sensor data; converting sensor data to a valuebased on a calibration of the sensor reading to the corresponding data;and/or combining data from one or more sensors or other information todetermine a value of interest). A sensor 2202 may be any type of sensoras set forth throughout the present disclosure, but includes at least aUT sensor, an EMI sensor (e.g., magnetic induction or the like), atemperature sensor, a pressure sensor, an optical sensor (e.g.,infrared, visual spectrum, and/or ultra-violet), a visual sensor (e.g.,a camera, pixel grid, or the like), or combinations of these.

The example system includes the inspection robot 100 and one or moreobstacle sensors 16440, e.g., lasers, cameras, sonars, radars, a ferroussubstrate detection sensor, contact sensors, etc., coupled to theinspection robot and/or otherwise disposed to detect obstacle in thepath of the inspection robot 100 as it inspects an inspection surface500.

The system further includes a controller 802 having a number of circuitsconfigured to functionally perform operations of the controller 802. Theexample controller 802 has an obstacle sensory data circuit 16402, anobstacle processing circuit 16406, an obstacle notification circuit16410, a user interface circuit 16414, and/or an obstacle configurationcircuit 16424. The example controller 802 may additionally oralternatively include aspects of any controller, circuit, or similardevice as described throughout the present disclosure. Aspects ofexample circuits may be embodied as one or more computing devices,computer-readable instructions configured to perform one or moreoperations of a circuit upon execution by a processor, one or moresensors, one or more actuators, and/or communications infrastructure(e.g., routers, servers, network infrastructure, or the like). Furtherdetails of the operations of certain circuits associated with thecontroller 802 are set forth, without limitation, elsewhere in thedisclosure

The example controller 802 is depicted schematically as a single devicefor clarity of description, but the controller 802 may be a singledevice, a distributed device, and/or may include portions at leastpartially positioned with other devices in the system (e.g., on theinspection robot 100). In certain embodiments, the controller 802 may beat least partially positioned on a computing device associated with anoperator of the inspection (not shown), such as a local computer at afacility including the inspection surface 500, a laptop, and/or a mobiledevice. In certain embodiments, the controller 802 may alternatively oradditionally be at least partially positioned on a computing device thatis remote to the inspection operations, such as on a web-based computingdevice, a cloud computing device, a communicatively coupled device, orthe like.

Accordingly, as illustrated in FIG. 47, the obstacle sensory datacircuit 16402 interprets obstacle sensory data 16404 comprising dataprovided by the obstacle sensors 16440. The obstacle sensory data mayinclude the position, type, traversal difficulty rating, imagery and/orany other type of information suitable for identifying the obstacle anddetermining a plan to overcome/traverse the obstacle. In embodiments,the obstacle sensory data 16404 may include imaging data from an opticalcamera of the inspection robot. The imaging data may be related to atleast one of: the body/structure of the obstacle, a position of theobstacle, a height of the obstacle, an inspection surface surroundingthe obstacle, a horizontal extent of the obstacle, a vertical extent ofthe obstacle, or a slope of the obstacle.

The obstacle processing circuit 16406 determines refined obstacle data16408 in response to the obstacle sensory data 16404. Refined obstacledata 16408 may include information distilled and/or derived from theobstacle sensory data 16404 and/or any other information that thecontroller 802 may have access to, e.g., pre-known and/or expectedconditions of the inspection surface.

The obstacle notification circuit 16410 generates and provides obstaclenotification data 16412 to a user interface device in response to therefined obstacle data 16408. The user interface circuit 16414 interpretsa user request value 16418 from the user interface device, anddetermines an obstacle response command value 16416 in response to theuser request value 16418. The user request value 16418 may correspond toa graphical user interface interactive event, e.g., menu selection,screen region selection, data input, etc.

The obstacle configuration circuit 16424 provides the obstacle responsecommand value 16416 to the inspection robot 100 during the interrogatingof the inspection surface 500. In embodiments, the obstacle responsecommand value 16416 may correspond to a reconfigure command 16420 theinspection robot and/or to adjust 16422 an inspection operation of theinspection robot. For example, in embodiments, the adjust inspectionoperation command 16422 may include a command that instructions theinspection robot to go around the obstacle, lift one or more payloads,change a downforce applied to one or more payloads, change a withbetween payloads and/or the sensors on the payloads, traverse/slide oneor more payloads to the left or to the right, change a speed at whichthe inspection robot traverses the inspection surface, to “test travel”the obstacle, e.g., to proceed slowly and observe, to mark (in realityor virtually) the obstacle, to alter the planned inspection route/pathof the inspection robot across the inspection surface, and/or to removea portion from an inspection map corresponding to the obstacle.

In embodiments, the obstacle response command value 16416 may include acommand to employ a device for mitigating the likelihood that theinspection robot will top over. Such device may include stabilizers,such as rods, mounted to and extendable away from the inspection robot.In embodiments, the obstacle response command value 16416 may include arequest to an operator to confirm the existence of the obstacle.Operator confirmation of the obstacle may be received as a user requestvalue 16418.

In embodiments, the obstacle configuration circuit 16424 determines,based at least in part on the refined obstacle data 16408, whether theinspection robot 100 has traversed an obstacle in response to executionof a command corresponding to the obstacle response command value 16416by the inspection robot 100. The obstacle configuration circuit 16424may determine that the obstacle has been traversed by detecting that theobstacle is no longer present in the obstacle sensory data 16404acquired by the obstacle sensors 16440. In embodiments, the obstacleprocessing circuit 16406 may be able to determine the location of theobstacle from the obstacle sensory data 16404 and the obstacleconfiguration circuit 16424 may determine that the obstacle has beentraversed by comparing the location of the obstacle to the location ofthe inspection robot. In embodiments, determining that an obstacle hasbeen successfully traversed may be based at least in part on detecting achange in a flow rate of couplant used to couple the inspection sensorsto the inspection surface. For example, a decrease in the couplant flowrate may indicate that the payload has moved past the obstacle.

The obstacle configuration circuit 16424 may provide an obstacle alarmdata value 16426 in response to determining that the inspection robot100 has not traversed the obstacle. As will be appreciated, inembodiments, the obstacle configuration circuit 16424 may provide theobstacle alarm data value 16426 regardless of whether traversal of theobstacle was attempted by the inspection robot 100. For example, theobstacle configuration circuit 16424 may provide the obstacle alarm datavalue 16426 as a command responsive to the obstacle response commandvalue 16416.

In embodiments, the obstacle processing circuit 16406 may determine therefined obstacle data 16408 as indicating the potential presence of anobstacle in response to comparing the obstacle data comprising aninspection surface depiction to a nominal inspection surface depiction.For example, the nominal inspection surface depiction may have beenderived based in part on inspection data previously acquired from theinspection surface at a time the conditions of the inspection surfacewere known. In other words, the nominal inspection surface depiction mayrepresent the normal and/or desired condition of the inspection surface500. In embodiments, the presence of an obstacle may be determined basedat least in part on an identified physical anomaly between obstaclesensory data 16404 and the nominal inspection surface data, e.g., adifference between acquired and expected image data, EMI readings,coating thickness, wall thickness, etc. For example, in embodiments, theobstacle processing circuit 16406 may determine the refined obstacledata 16408 as indicating the potential presence of an obstacle inresponse to comparing the refined obstacle data 16408, which may includean inspection surface depiction, to a predetermined obstacle inspectionsurface depiction. As another example, the inspection robot may identifya marker on the inspection surface and compare the location of theidentified marker to an expected location of the marker, withdifferences between the two indicating a possible obstacle. Inembodiments, the presence of an obstacle may be determined based ondetecting a change in the flow rate of the couplant that couples theinspection sensors to the inspection surface. For example, an increasein the couplant flow rate may indicate that the payload has encounteredan obstacle that is increasing the spacing between the inspectionsensors and the inspection surface.

In embodiments, the obstacle notification circuit 16410 may provide theobstacle notification data 16412 as at least one of an operator alertcommunication and/or an inspection surface depiction of at least aportion of the inspection surface. The obstacle notification data 16412may be presented to an operator in the form of a pop-up picture and/orpop-up inspection display. In embodiments, the obstacle notificationdata 16412 may depict a thin or non-ferrous portion of the inspectionsurface. In embodiments, information leading to the obstacle detectionmay be emphasized, e.g., circled, highlighted, etc. For example,portions of the inspection surface identified as being cracked may becircled while portions of the inspection surface covered in dust may behighlighted.

In embodiments, the obstacle processing circuit 16406 may determine therefined obstacle data 16408 as indicating the potential presence of anobstacle in response to determining a non-ferrous substrate detection ofa portion of the inspection surface and/or a reduced magnetic interfacedetection of a portion of the inspection surface. Examples of reducedmagnetic interface detection include portions of a substrate/inspectionsurface lacking sufficient ferrous material to support the inspectionrobot, lack of a coating, accumulation of debris and/or dust, and/or anyother conditions that may reduce the ability of the magnetic wheelassemblies to couple the inspection robot to the inspection surface.

In embodiments, the obstacle notification circuit 16410 may provide astop command to the inspection robot in response to the refined obstacledata 16408 indicating the potential presence of an obstacle.

In embodiments, the obstacle response command value 16416 may include acommand to reconfigure an active obstacle avoidance system of theinspection robot 100. Such a command may be a command to: reconfigure adown force applied to one or more payloads coupled to the inspectionrobot; reposition a payload coupled to the inspection robot; lift apayload coupled to the inspection robot; lock a pivot of a sled, thesled housing and/or an inspection sensor of the inspection robot; unlocka pivot of a sled, the sled housing and/or an inspection sensor of theinspection robot; lock a pivot of an arm, the arm coupled to a payloadof the inspection robot, and/or an inspection sensor coupled to the arm;unlock a pivot of an arm, the arm coupled to a payload of the inspectionrobot, and/or an inspection sensor coupled to the arm; rotate a chassisof the inspection robot relative to a drive module of the inspectionrobot; rotate a drive module of the inspection robot relative to achassis of the inspection robot; deploy a stability assist devicecoupled to the inspection robot; reconfigure one or more payloadscoupled to the inspection robot; and/or adjust a couplant flow rate ofthe inspection robot. In certain embodiments, adjusting the couplantflow rate is performed to ensure acoustic coupling between a sensor andthe inspection surface, to perform a re-coupling operation between thesensor and the inspection surface, to compensate for couplant lossoccurring during operations, and/or to cease or reduce couplant flow(e.g., if the sensor, an arm, and/or a payload is lifted from thesurface, and/or if the sensor is not presently interrogating thesurface). An example adjustment to the couplant flow includes adjustingthe couplant flow in response to a reduction of the down force (e.g.,planned or as a consequence of operating conditions), where the couplantflow may be increased (e.g., to preserve acoustic coupling) and/ordecreased (e.g., to reduce couplant losses).

Turning now to FIG. 48, a method for traversing an obstacle with aninspection robot is shown. The method may include interpreting 16502obstacle sensory data comprising data provided by an inspection robot,determining 16504 refined obstacle data in response to the obstaclesensory data; and generating 16506 an obstacle notification in responseto the refined obstacle data. The method may further include providing16508 the obstacle notification data to a user interface. The method mayfurther include interpreting 16510 a user request value, determining16512 an obstacle response command value in response to the user requestvalue; and providing 16514 the obstacle command value to the inspectionrobot during an inspection run. In embodiments, the method may furtherinclude adjusting 16516 an inspection operation of the inspection robotin response to the obstacle response command value. In embodiments,adjusting 16516 the inspection operation may include stopping 16618interrogation of the inspection surface. In embodiments, adjusting 16516the inspection operation may include updating 16620 an inspection runplan. In embodiments, adjusting 16516 the inspection operation mayinclude taking 16650 data in response to the obstacle. In embodiments,adjusting 16516 the inspection operation may include applying a virtualmark. In embodiments, adjusting 16516 the inspection operation mayinclude updating 16654 an obstacle map. In embodiments, adjusting 16516the inspection operation may include acquiring 16656 an image and/orvideo of the obstacle. In embodiments, adjusting 16516 the inspectionoperation may include confirming 16658 the obstacle.

The method may further include reconfiguring 16518 an active obstacleavoidance system. In embodiments, reconfiguring 16518 the activeobstacle avoidance system may include adjusting 16624 a down forceapplied to one or more payloads coupled to the inspection robot. Inembodiments, reconfiguring 16518 the active obstacle avoidance systemmay include reconfiguring 16626 one or more payloads coupled to theinspection robot. Reconfiguring 16626 the one or more payloads mayinclude adjusting a width between the payloads and/or one or moresensors on the payloads. In embodiments, reconfiguring 16518 the activeobstacle avoidance system may include adjusting 16628 a couplant flowrate. In embodiments, reconfiguring 16518 the active obstacle avoidancesystem may include lifting 16630 one or more payloads coupled to theinspection robot. In embodiments, reconfiguring 16518 the activeobstacle avoidance system may include locking 16632 and/or unlocking16634 the pivot of a sled of a payload coupled to the inspection robot.In embodiments, reconfiguring 16518 the active obstacle avoidance systemmay include locking 16636 and/or unlocking 16638 the pivot of an armthat couples a sled to a body of a payload or to the inspection robotchassis. In embodiments, reconfiguring 16518 the active obstacleavoidance system may include rotating 16640 the inspection robotchassis. In embodiments, reconfiguring 16518 the active obstacleavoidance system may include rotating 16646 a drive module coupled tothe inspection robot. In embodiments, reconfiguring 16518 the activeobstacle avoidance system may include repositioning 16644 a payloadcoupled to the inspection robot.

In embodiments, the method may further include determining 16520 whetherthe inspection robot traversed the obstacle. In embodiments, the methodmay further include providing 16522 a data alarm in response todetermining 16520 that the inspection robot has not traversed theobstacle.

Any one or more of the specified times related to interactions betweenthe entities may be defined by contractual terms related to theinspection operation, industry standard practices related to theinspection operation, an understanding developed between the entitiesrelated to the inspection operation, and/or the ongoing conduct of theentities for a number inspection operations related to the inspectionoperation, where the number of inspection operations may be inspectionoperations for related facilities, related inspection surfaces, and/orprevious inspection operations for the inspection surface. One of skillin the art, having the benefit of the disclosure herein and informationordinarily available when contemplating a particular system and/orinspection robot, can readily determine validation operations andvalidation time periods that are rapid validations for the purposes ofthe particular system.

A response, as used herein, and without limitation to any other aspectof the present disclosure, includes an adjustment to at least one of: aninspection configuration for the inspection robot while on the surface(e.g., a change to sensor operations; couplant operations; robottraversal commands and/or pathing; payload configurations; and/or downforce configuration for a payload, sled, sensor, etc.); a change todisplay operations of the inspection data; a change to inspection dataprocessing operations, including determining raw sensor data, minimalprocessing operations, and/or processed data values (e.g., wallthickness, coating thickness, categorical descriptions, etc.); aninspection configuration for the inspection robot performed with theinspection robot removed from the inspection surface (e.g., changedwheel configurations, changed drive module configurations; adjustedand/or swapped payloads; changes to sensor configurations (e.g.,switching out sensors and/or sensor positions); changes to hardwarecontrollers (e.g., switching a hardware controller, changing firmwareand/or calibrations for a hardware controller, etc.); and/or changing atether coupled to the inspection robot. The described responses arenon-limiting examples, and any other adjustments, changes, updates, orresponses set forth throughout the present disclosure are contemplatedherein for potential rapid response operations. Certain responses aredescribed as performed while the inspection robot is on the inspectionsurface and other responses are described as performed with theinspection robot removed from the inspection surface, although any givenresponse may be performed in the other condition, and the availabilityof a given response as on-surface or off-surface may further depend uponthe features and configuration of a particular inspection robot, as setforth in the multiple embodiments described throughout the presentdisclosure. Additionally or alternatively, certain responses may beavailable only during certain operating conditions while the inspectionrobot is on the inspection surface, for example when the inspectionrobot is in a location physically accessible to an operator, and/or whenthe inspection robot can pause physical movement and/or inspectionoperations such as data collection. One of skill in the art, having thebenefit of the present disclosure and information ordinarily availablewhen contemplating a particular system and/or inspection robot, canreadily determine response operations available for the particularsystem and/or inspection robot.

A response that is rapid, as used herein, and without limitation to anyother aspect of the present disclosure, includes a response capable ofbeing performed in a time relevant to the considered downstreamutilization of the response. For example, a response that can beperformed during the inspection operation, and/or before the completionof the inspection operation, may be considered a rapid response incertain embodiments, allowing for the completion of the inspectionoperation utilizing the benefit of the rapid response. Certain furtherexample rapid response times include: a response that can be performedat the location of the inspection surface (e.g., without requiring theinspection robot be returned to a service or dispatching facility forreconfiguration); a response that can be performed during a period oftime wherein a downstream customer (e.g., an owner or operator of afacility including the inspection surface; an operator of the inspectionrobot performing the inspection operations; and/or a user related to theoperator of the inspection robot, such as a supporting operator,supervisor, data verifier, etc.) of the inspection data is reviewing theinspection data and/or a visualization corresponding to the inspectiondata; and/or a response that can be performed within a specified periodof time (e.g., before a second inspection operation of a secondinspection surface at a same facility including both the inspectionsurface and the second inspection surface; within a specified calendarperiod such as a day, three days, a week, etc.). An example rapidresponse includes a response that can be performed within a specifiedtime related to interactions between an entity related to the operatorof the inspection robot and an entity related to a downstream customer.For example, the specified time may be a time related to an invoicingperiod for the inspection operation, a warranty period for theinspection operation, a review period for the inspection operation, andor a correction period for the inspection operation. Any one or more ofthe specified times related to interactions between the entities may bedefined by contractual terms related to the inspection operation,industry standard practices related to the inspection operation, anunderstanding developed between the entities related to the inspectionoperation, and/or the ongoing conduct of the entities for a numberinspection operations related to the inspection operation, where thenumber of inspection operations may be inspection operations for relatedfacilities, related inspection surfaces, and/or previous inspectionoperations for the inspection surface. One of skill in the art, havingthe benefit of the disclosure herein and information ordinarilyavailable when contemplating a particular system and/or inspectionrobot, can readily determine response operations and response timeperiods that are rapid responses for the purposes of the particularsystem.

Certain considerations for determining whether a response is a rapidresponse include, without limitation, one or more of: the purpose of theinspection operation, how the downstream customer will utilize theinspection data from the inspection operation, and/or time periodsrelated to the utilization of the inspection data; entity interactioninformation such as time periods wherein inspection data can be updated,corrected, improved, and/or enhanced and still meet contractualobligations, customer expectations, and/or industry standard obligationsrelated to the inspection data; source information related to theresponse, such as whether the response addresses an additional requestfor the inspection operation after the initial inspection operation wasperformed, whether the response addresses initial requirements for theinspection operation that were available before the inspection operationwas commenced, whether the response addresses unexpected aspects of theinspection surface and/or facility that were found during the inspectionoperations, whether the response addresses an issue that is attributableto the downstream customer and/or facility owner or operator, such as:inspection surface has a different configuration than was indicated atthe time the inspection operation was requested; the facility owner oroperator has provided inspection conditions that are different thanplanned conditions, such as couplant availability, couplant composition,couplant temperature, distance from an available base station locationto the inspection surface, coating composition or thickness related tothe inspection surface, vertical extent of the inspection surface,geometry of the inspection surface such as pipe diameters and/or tankgeometry, availability of network infrastructure at the facility,availability of position determination support infrastructure at thefacility, operating conditions of the inspection surface (e.g.,temperature, obstacles, etc.); additional inspected conditions arerequested than were indicated at the time of the inspection operationwas requested; and/or additional inspection robot capabilities such asmarking, repair, and/or cleaning are requested than were indicated atthe time the inspection operation was requested.

In a further example, the user observes the refined inspection data,such as in a display or visualization of the inspection data, andprovides the user response command in response to the refined inspectiondata, for example requesting that additional data or data types becollected, requesting that additional conditions (e.g., anomalies,damage, condition and/or thickness of a coating, higher resolutiondeterminations—either spatial resolution such as closer or more sparsedata collection positions, or sensed data resolution such as higher orlower precision sensing values, etc.) be inspected, extending theinspection surface region to be inspected, and/or omitting inspection ofregions of the inspection surface that were originally planned forinspection. In certain embodiments, the user response command allows theuser to change inspection operations in response to the results of theinspection operations, for example where the inspection surface is foundto be in a better or worse condition than expected, where an unexpectedcondition or data value is detected during the inspection, and/or whereexternal considerations to the inspection occur (e.g., more or less timeare available for the inspection, a system failure occurs related to thefacility or an offset facility, or the like) and the user wants to makea change to the inspection operations in response to the externalcondition. In certain embodiments, the user response command allows forthe user to change inspection operations in response to suspectedinvalid data (e.g., updating sensor calibrations, performing couplingoperations to ensure acoustic coupling between a sensor and theinspection surface, and/or repeating inspection operations to ensurethat the inspection data is repeatable for a region of the inspectionsurface), in response to a condition of the inspection surface such asan assumed value (e.g., wall thickness, coating thickness and/orcomposition, and/or presence of debris) that may affect processing therefined inspection data, allowing for corrections or updates to sensorsettings, couplant flow rates, down force provisions, speed of theinspection robot, distribution of sensors, etc. responsive to thedifference in the assumed value and the inspection determined conditionof the inspection surface.

The example utilizes x-y coverage resolution to illustrate theinspection surface as a two-dimensional surface having a generallyhorizontal (or perpendicular to the travel direction of the inspectionrobot) and vertical (or parallel to the travel direction of theinspection robot) component of the two-dimensional surface. However, itis understood that the inspection surface may have a three-dimensionalcomponent, such as a region within a tank having a surface curvaturewith three dimensions, a region having a number of pipes or otherfeatures with a depth dimension, or the like. In certain embodiments,the x-y coverage resolution describes the surface of the inspectionsurface as traversed by the inspection robot, which may be twodimensional, conceptually two dimensional with aspects have a threedimensional component, and/or three dimensional. The description ofhorizontal and vertical as related to the direction of travel is anon-limiting example, and the inspection surface may have a firstconceptualization of the surface (e.g., x-y in a direction unrelated tothe traversal direction of the inspection robot), where the inspectionrobot traverses the inspection surface in a second conceptualization ofthe surface (e.g., x-y axes oriented in a different manner than the x-ydirections of the first conceptualization), where the operations of theinspection robot such as movement paths and/or sensor inspectionlocations performed in the second conceptualization are transformed andtracked in the first conceptualization.

While the first conceptualization and the second conceptualization aredescribed in relation to a two-dimensional description of the inspectionsurface for clarity of the present description, either or both of thefirst conceptualization and the second conceptualization may includethree-dimensional components and/or may be three-dimensionaldescriptions of the inspection surface. In certain embodiments, thefirst conceptualization and the second conceptualization may be the sameand/or overlay each other (e.g., where the traversal axes of the robotdefine the view of the inspection surface, and/or where the axes of theinspection surface view and the traversal axes of the robot coincide).

While the first conceptualization and the second conceptualization aredescribed in terms of the inspection robot traversal and the user deviceinterface, additional or alternative conceptualizations are possible,such as in terms of an operator view of the inspection surface, otherusers of the inspection surface, and/or analysis of the inspectionsurface (e.g., where aligning one axis with a true vertical of theinspection surface, aligning an axis with a temperature gradient of theinspection surface, or other arrangement may provide a desirable featurefor the conceptualization for some purpose of the particular system).

In certain embodiments, the user may provide a desired conceptualization(e.g., orientation of x-y axes, etc.) as a user response command, and/oras any other user interaction as set forth throughout the presentdisclosure, allowing for the user to interface with depictions of theinspection surface in any desired manner. It can be seen that theutilization of one or more conceptualizations of the inspection surfaceprovide for simplification of certain operations of aspects of systems,procedures, and/or controllers throughout the present disclosure (e.g.,user interfaces, operator interfaces, inspection robot movementcontrols, etc.). It can be seen that the utilization of one or moreconceptualizations of the inspection surface allow for combinedconceptualizations that have distinct dimensionality, such astwo-dimensional for a first conceptualization (e.g., traversal commandsand/or sensor distributions for an inspection robot operating on acurved surface such as a tank interior, where the curved surfaceincludes a related three-dimensional conceptualization; and/or where afirst conceptualization eliminates the need for a dimension, such as byaligning an axis perpendicular to a cylindrical inspection surface), anda either three-dimensional or a non-simple transformation to a differenttwo-dimensional for a second conceptualization (e.g., aconceptualization having an off-perpendicular axis for a cylindricalinspection surface, where a progression of that axis along theinspection surface would be helical, leading to either a threedimensional conceptualization, or a complex transformed two dimensionalconceptualization).

Referencing FIG. 55, an example system for providing real-time processedinspection data to a user is depicted. The example system includes aninspection robot 100 positioned on an inspection surface 500. Theexample inspection robot 100 includes any inspection robot having anumber of sensors associated therewith and configured to inspect aselected area. Without limitation to any other aspect of the presentdisclosure, an inspection robot 100 as set forth throughout the presentdisclosure, including any features or characteristics thereof, iscontemplated for the example system depicted in FIG. 55. In certainembodiments, the inspection robot 100 may have one or more payloads, andmay include one or more sensors on each payload.

The example system may include a controller 21002 having a number ofcircuits configured to functionally perform operations of the controller21002. The example system includes the controller 21002 having aninspection data circuit that interprets inspection base data from thesensors 2202, an inspection processing circuit that determines refinedinspection data in response to the inspection base data, and a userinterface circuit that provides the refined inspection data to a userinterface device 21006. The user interface circuit further communicateswith the user interface device 21006, for example to interpret a userrequest value such as a request to change a display value, to changeinspection parameters, and/or to perform marking, cleaning, and/orrepair operations related to the inspection surface 500. The examplecontroller 21002 may additionally or alternatively include aspects ofany controller, circuit, or similar device as described throughout thepresent disclosure. Aspects of example circuits may be embodied as oneor more computing devices, computer-readable instructions configured toperform one or more operations of a circuit upon execution by aprocessor, one or more sensors, one or more actuators, and/orcommunications infrastructure (e.g., routers, servers, networkinfrastructure, or the like).

The example controller 21002 is depicted schematically as a singledevice for clarity of description, but the controller 21002 may be asingle device, a distributed device, and/or may include portions atleast partially positioned with other devices in the system (e.g., onthe inspection robot 100, or the user interface device 21006). Incertain embodiments, the controller 21002 may be at least partiallypositioned on a computing device associated with an operator of theinspection (not shown), such as a local computer at a facility includingthe inspection surface 500, a laptop, and/or a mobile device. In certainembodiments, the controller 21002 may alternatively or additionally beat least partially positioned on a computing device that is remote tothe inspection operations, such as on a web-based computing device, acloud computing device, a communicatively coupled device, or the like.

Referring to FIG. 55, in certain embodiments, a controller 21002 maycommunicate to the user interface device 21006 using an intermediatestructure 21004, such as a web portal, mobile application service,network connection, or the like. In certain embodiments, theintermediate structure 21004 may be varied by the controller 21002and/or a user 21008, for example allowing the user 21008 to connect tothe controller 21002 using a web portal at one time, and a mobileapplication at a different time. The controller 21002 may includeoperations such as performing an authentication operation, a loginoperation, or other confirmation that a user 21008 is authorized tointeract with the controller 21002. In certain embodiments, theinteractions of the user 21008 may be limited according to permissionsrelated to the user 21008, the user interface device 21006, and/or anyother considerations (e.g., a location of the user, an operating stageof an inspection, a limitation imposed by an operator of the inspection,etc.). In certain embodiments, and/or during certain operatingconditions, the controller 21002 communicates directly with the userinterface device 21006, and/or the user 21008 may interface directlywith a computing device having at least a portion of the controller21002 positioned thereon.

Referring to FIG. 56, an example system 21600 includes an inspectionrobot 21602 that interprets inspection base data including data providedby an inspection robot interrogating an inspection surface with aplurality of inspection sensors. The inspection robot 21602 may includean inspection robot configured according to any of the embodiments oraspects as set forth in the present disclosure.

The example system 21600 includes a controller 21604 configured toperform rapid inspection data validation operations. The controller21604 includes a number of circuits configured to functionally executeoperations of the controller 21604. An example controller 21604 includesan inspection data circuit that interprets inspection base datacomprising data provided by the inspection robot interrogating theinspection surface with a number of inspection sensors, an inspectionprocessing circuit that determines refined inspection data in responseto the inspection base data, an inspection data validation circuit thatdetermines an inspection data validity value in response to the refinedinspection data, and a user communication circuit that provides a datavalidity description to a user device in response to the inspection datavalidity value. The example system 21600 further includes a user device21606 that is communicatively coupled to the controller 21604. The userdevice 21606 is configured to provide a user interface for interactingoperations of the controller 21604 with the user 21610, includingproviding information, alerts, and/or notifications to the user 21610,receiving user requests or inputs and communicating those to thecontroller 21604, and accessing a data store 21608, for example toprovide access to data for the user 21610.

The example system further includes the inspection data circuitresponsive to the user request value to adjust the interpretedinspection base data and/or the interrogation of the inspection surface.For example, and without limitation, the user request value may providefor a change to an inspection resolution (e.g., a horizontal distancebetween sensors 2202, a vertical distance at which sensor sampling isperformed, selected positions of the inspection surface 500 to beinterrogated, etc.), a change to sensor values (e.g., sensor resolutionsuch as dedicated bits for digitization; sensor scaling; sensorcommunicated data parameters; sensor minimum or maximum values, etc.), achange to the planned location trajectory of the inspection robot (e.g.,scheduling additional inspection passes, changing inspected areas,canceling planned inspection portions, adding inspection portions,etc.), and/or a change in sensor types (e.g., adding, removing, orreplacing utilized sensors). In certain embodiments, the inspection datacircuit responds to the user request value by performing an inspectionoperation that conforms with the user request value, by adjustinginspection operations to incrementally change the inspection scheme tobe closer to the user request value (e.g., where the user request valuecannot be met, where other constraints prevent the user request valuefrom being met, and/or where permissions of the user 21008 allow onlypartial performance of the user request value). In certain embodiments,a difference between the user request value and the adjusted interpretedinspection base data and/or interrogation scheme may be determined,and/or may be communicated to the user, an operator, an administrator,another entity, and/or recorded in association with the data (e.g., as adata field, metadata, label for the data, etc.).

In certain embodiments, the inspection processing circuit is responsiveto the user request value to adjust the determination of the refinedinspection data. In certain embodiments, certain sensed values utilize asignificant amount of post-processing to determine a data value. Forexample, a UT sensor may output a number of return times, which may befiltered, compared to thresholds, subjected to frequency analysis, orthe like. In certain embodiments, the inspection base data includesinformation provided by the sensor 2202, and/or information provided bythe inspection robot 100 (e.g., using processing capability on theinspection robot 100, hardware filters that act on the sensor 2202 rawdata, de-bounced data, etc.). The inspection base data may be rawdata—for example the actual response provided by the sensor such as anelectronic value (e.g., a voltage, frequency, or current output), butthe inspection base data may also be processed data (e.g., return times,temperature, pressure, etc.). As utilized herein, the refined inspectiondata is data that is subjected to further processing, generally to yielddata that provides a result value of interest (e.g., a thickness, or astate value such as “conforming” or “failed”) or that provides autilizable input for another model or virtual sensor (e.g., a correctedtemperature, corrected flow rate, etc.). Accordingly, the inspectionbase data includes information from the sensor, and/or processedinformation from the sensor, while the refined inspection data includesinformation from the inspection base data that has been subjected tofurther processing. In certain embodiments, the computing time and/ormemory required to determine the refined inspection data can be verysignificant. In certain embodiments, determination of the refinedinspection data can be improved with the availability of significantadditional data, such as data from offset and/or related inspectionsperformed in similar systems, calibration options for sensors, and/orcorrection options for sensors (e.g., based on ambient conditions;available power for the sensor; materials of the inspection surface,coatings, or the like; etc.). Accordingly, in previously known systems,the availability of refined inspection data was dependent upon themeeting of the inspection base data with significant computing resources(including processing, memory, and access to databases), introducingsignificant delays (e.g., downloading data from the inspection robot 100after an inspection is completed) and/or costs (e.g., highly capablecomputing devices on the inspection robot 100 and/or carried by aninspection operator) before the refined inspection data is available foranalysis. Further, previously known systems do not allow for theutilization of refined inspection data during inspection operations(e.g., making an adjustment before the inspection operation is complete)and/or utilization by a customer of the data (e.g., a user 21008) thatmay have a better understanding of the commercial considerations of theinspection output than an inspection operator.

Example and non-limiting inspection adjustments include adjusting aninspection location trajectory of the inspection robot (e.g., the regionof the inspection surface to be inspected, the inspection pathing on theinspection surface, and/or the spatial order of inspection of theinspection surface), adjusting a calibration value of one of theinspection sensors (e.g., A/D conversion values, UT calibrations and/orassumptions utilized to process signals, and/or other parametersutilized to operate sensors, interpret data, and/or post-process datafrom sensors), and/or a command to enable at least one additionalinspection sensor (e.g., activating an additional sensor, receiving dataprovided by the sensor, and/or storing data provided by the sensor). Incertain embodiments, the at least one additional inspection sensor is asensor having a different type of sensing relative to a previouslyoperating sensor, and/or a sensor having a different capability and/ordifferent position on the inspection robot (e.g., positioned on adifferent payload, different sled, and/or at a different position on asled). Example and non-limiting additional inspection operations includere-inspecting at least portion of the inspection surface, performing aninspection with a sensor having distinct capabilities, sensing type,and/or calibrations relative to a previously operating sensor,inspecting additional regions of the inspection surface beyond aninitially planned region, changing an inspection resolution (e.g., aspacing between sensed locations), changing a traversal speed of theinspection robot during inspection operations, or the like.

In certain embodiments, a marking operation includes mitigationoperations (e.g., to extend a service time, allow a facility to continueoperations, and/or provide time to allow for additional inspections orsubsequent service or repair to be performed), inspection operations(e.g., gathering more detailed information, confirming information,imaging information, etc. related to the marked region), and/or cleaningoperations (e.g., to ensure that data collection is reliable, to ensurethat a mark adheres and/or can be seen, and/or to enhance relatedimaging information) for the marked region of the inspection surfaceand/or adjacent regions.

Example alternate embodiments for sleds, arms, payloads, and sensorinterfaces, including sensor mounting and/or sensor electronic coupling,are described herein. Variations may be included in embodiments ofinspection robots, payloads, arms, sleds, and arrangements of these asdescribed throughout the present disclosure. Variations may includefeatures that provide for, without limitation, ease of integration,simplified coupling, and/or increased options to achieve selectedhorizontal positioning of sensors, selected horizontal sensor spacing,increased numbers of sensors on a payload and/or inspection robot,and/or increased numbers of sensor types available within a givengeometric space for an inspection robot.

Referencing FIG. 51, an example payload having an arm and two sledsmounted thereto is depicted. In certain embodiments, the arrangement ofFIG. 51 forms a portion of a payload, for example as an arm coupled to apayload at a selected horizontal position. In certain embodiments, thearrangement of FIG. 51 forms a payload, for example coupled at aselected horizontal position to a rail or other coupling feature of aninspection robot chassis, thereby forming a payload having a number ofinspection sensors mounted thereon. The example of FIG. 51 includessleds and sensor group housings that are consistent with embodimentselsewhere herein. The example of FIG. 51 includes an arm 19802 couplingthe sled to a payload coupling 19810 (and/or chassis coupling 19810).The arm 19802 defines a passage therethrough, wherein a couplantconnection may pass through the passage, or may progress above the armto couple with the sensor lower body portion. The arrangement of FIG. 51provides multiple degrees of freedom for movement of the sled, any oneor more of which may be present in certain embodiments. For example, thepivot coupling 19812 of the arm 19802 to the sled allows for pivoting ofthe sled relative to the arm 19802, and each sled of the pair of sledsdepicted may additionally or alternatively pivot separately or becoupled to pivot together (e.g., pivot coupling 19812 may be a singleaxle, or separate axles coupled to each sled). The arm coupling 19804provides for pivoting of the arm 19802 relative to the inspectionsurface (e.g., raising or lowering), and a second arm coupling 19816provides for rotation of the arm 19802 (and coupling joint 19814) alonga second perpendicular axis relative to arm coupling 19804. Accordingly,couplings 19804, 19816 operate together to in a two-axis gimbalarrangement, allowing for rotation in one axis, and pivoting in theother axis. The selected pivoting and/or rotational degrees of freedomare selectable, and one or more of the pivoting or rotational degrees offreedom may be omitted, limited in available range of motion, and/or beassociated with a biasing member that urges the movement in a selecteddirection and/or urges movement back toward a selected position. In theexample of FIG. 52, a biasing spring 19806 urges the pivot coupling19812 to move the arm 19802 toward the inspection surface, therebycontributing to a selected downforce on the sled. Any one or more of thebiasing members may be passive (e.g., having a constant arrangementduring inspection operations) and/or active (e.g., having an actuatorthat adjusts the arrangement, for example changing a force of theurging, changing a direction of the urging, and/or changing the selectedposition of the urging. The example of FIG. 51 depicts selected ramps19704 defined by the sled, and sensor group housing 19200 elementspositioned on each sled and coupling the sensors to the sled and/or theinspection surface. The example of FIG. 50 further includes a couplingline retainer 19808 that provides for routing of couplant lines and/orelectrical communication away from rotating, pivoting, or movingelements, and provides for consistent positioning of the couplant linesand/or electrical communication for ease of interfacing the arrangementof FIG. 51 with a payload and/or inspection chassis upon which thearrangement is mounted. The example payload coupling 19810 includes aclamp having a moving portion and a stationary portion, and may beoperable with a screw, a quick connect element (e.g., a wing nut and/orcam lever arrangement), or the like. The example payload coupling 19810is a non-limiting arrangement, and the payload/chassis coupling mayinclude any arrangement, including, without limitation, a clamp, acoupling pin, an R-clip (and/or a pin), a quick connect element, orcombinations among these elements.

Referencing FIG. 53, an example arrangement is depicted. The example ofFIG. 53 may form a payload or a portion of a payload (e.g., with thearms coupled to the corresponding payload), and/or the example of FIG.53 may depict two payloads (e.g., with the arms coupled to a feature ofthe inspection robot chassis). The arrangement of FIG. 53 is consistentwith the arrangement of FIG. 51, and depicts two arm assemblies in anexample side-by-side arrangement. In an example embodiment wherein eachsensor group housing 19200 includes six sensors mounted therein, theexample of FIG. 51 illustrates how an arrangement of 24 sensors can bereadily positioned on an inspection surface, with each of the sensorshaving a separate and configurable horizontal position on the inspectionsurface, allowing for rapid inspection of the inspection surface and/orhigh resolution (e.g., horizontal distance between adjacent sensors)inspection of the inspection surface. An example embodiment includeseach arm having an independent couplant and/or electrical interface,allowing for a switch of 12 sensors at a time with a single couplantand/or electrical connection to be operated. An example embodimentincludes the arms having a shared couplant interface (e.g., referenceFIG. 34) allowing for a switch of 24 sensors at a time with a singlecouplant connection to be operated. The pivotal and rotational couplingsand/or degrees of freedom available may be varied between the arms, forexample to allow for greater movement in one arm versus another (e.g.,to allow an arm that is more likely to impact an obstacle, such as anouter one of the arms, to have more capability to deflect away fromand/or around the obstacle).

Referencing FIG. 52, an example arrangement is depicted as a top view,consistent with the arrangement of FIG. 51. It can be seen that thesensor group housings 19200 can readily be configured to provide forselected horizontal distribution of the inspection sensors. Thehorizontal distribution can be adjusted by replacing the arms with armshaving a different sensor group housing 19200 and sensor arrangementwithin the sensor group housing 19200, by displacing the arms along apayload and/or along the inspection robot chassis, and/or displacing apayload (where the arms are mounted to the payload) along the inspectionrobot chassis.

FIG. 53 depicts a bottom view of two sled body lower portions 19706 in apivoted position. The example of FIG. 53 is a schematic depiction ofsled body lower portions, with the sled bottom surface omitted. Incertain embodiments, the inspection robot may be operated with the sledlower body portions 19706 in contact with the inspection surface, andaccordingly the sled bottom surface may be omitted. Additionally, thedepiction of FIG. 53 with the sled bottom surface portion omitted allowsfor depiction of certain features of the example sled body lowerportions 19706. The example of FIG. 53 includes sled body lower portions19706 having coupling slots 20202 engageable with matching coupling tabsof the sled bottom surface. The number and position of the slots 20202and/or tabs is a non-limiting example, and a sled body lower portion19706 may include slots 20202 that are not utilized by a particular sledbottom surface, for example to maintain compatibility with a number ofsled bottom surface components. In certain embodiments, the slots 20202positioned on the sled body lower portions 19706 rather than on the sledbottom surface portions allow for the sleds to be operated without thesled bottom surface. In certain embodiments, the slots 20202 may bepresent on the sled bottom surface, and the tabs may be present on thesled body lower portions 19706, and/or the slots 20202 and tabs may bemixed between the sled bottom surface, and the tabs may be present onthe sled body lower portions 19706. The sled lower portions 19706 mayinclude openings 19708 to allow sensors to engage with an inspectionsurface.

In certain embodiments, an inspection robot and/or payload arrangementmay be configured to engage a flat inspection surface, for example atFIG. 51. The depiction of FIG. 51 engageable to a flat inspectionsurface is a non-limiting example, and an arrangement otherwiseconsisting with FIG. 51 may be matched, utilizing sled bottom surfaces,overall sled engagement positions, or freedom of relative movement ofsleds and/or arms to engage a curved surface, a concave surface, aconvex surface, and/or combinations of these (e.g., a number of parallelpipes having undulations, varying pipe diameters, etc.). An inspectionrobot and/or payload arrangement as set forth herein may be configuredto provide a number of inspection sensors distributed horizontally andoperationally engaged with the inspection surface, where movement on theinspection surface by the inspection robot moves the inspection sensorsalong the inspection surface. In certain embodiments, the arrangement isconfigurable to ensure the inspection sensors remain operationallyengaged with a flat inspection surface, with a concave inspectionsurface, and/or with a convex inspection surface. Additionally, thearrangement is configurable, for example utilizing pivotal and/orrotation arrangements of the arms and/or payloads, to maintainoperational contact between the inspection sensors and an inspectionsurface having a variable curvature. For example, an inspection robotpositioned within a large concave surface such as a pipe or acylindrical tank, where the inspection robot moves through a verticalorientation (from the inspection robot perspective) is not eitherparallel to or perpendicular to a longitudinal axis of the pipe, willexperience a varying concave curvature with respect to the horizontalorientation (from the inspection robot perspective), even where the pipehas a constant curvature (from the perspective of the pipe). In anotherexample, an inspection robot traversing an inspection surface havingvariable curvature, such as a tank having an ellipsoid geometry, or acylindrical tank having caps with a distinct curvature relative to thecylindrical body of the tank.

Referring to FIG. 57 depicts an example inspection robot 21700. Theinspection robot 21700 includes a number of aspects, components,assemblies, and the like arranged to illustrate aspects of the presentdisclosure. Aspects of the inspection robot 21700 may be combined, inwhole or part, with other embodiments depicted throughout the presentdisclosure. Aspects of other embodiments may be included with and/orcombined, in whole or part, the inspection robot 21700 and/or aspectsthereof. The inspection robot 21700 may include a housing 21702 and oneor more drive modules 21704. The drive modules 21704 include a motor21706 and a wheel 21708. Coolant hoses 21712, 21714 enable the flow ofcoolant throughout the inspection robot 21700. The coolant mayadditionally be utilized as a couplant, and/or may be referenced as acouplant in embodiments of the present disclosure. Coolant may flowthrough coolant hose 21712 from a housing 21702 to a drive module 21704.Coolant may flow through coolant hose 21714 between drive modules 21704.A tether 21710 may connect the inspection robot 21700 to an externaldevice. A center encoder 21718 may be attached to the center of thehousing 21702.

As seen in FIG. 57, drive modules may rotate 21720 independently aroundan axis approximately parallel to the direction of travel. In certainembodiments, each drive module on a side (e.g., where one side includesmore than one drive module) may rotate independently, for example on anaxis parallel to the direction of travel, perpendicular to the directionof travel, and/or in any other rotational degree of freedom that isdesired. The independent rotation of the drive modules allows forimproved traversal of obstacles, navigating irregular or highly curvedsurfaces, navigation of the inspection robot (e.g., for turning,reversing direction, including on curved surfaces), or the like.

The embodiments of FIGS. 58-59 are consistent with certain aspects ofthe inspection robot 21700, and may be included in whole or part, withthe inspection robot 21700 or other embodiments depicted throughout thepresent disclosure. Referring to FIG. 58, partial view 21800 of aninspection robot is shown. A wheel 21708 may include a rare earth magnet21802, magnetic shielding 21804 and serrated tires 21806.

Referring to FIG. 59, a drive module 21704 may be seen. A drive modulemay include coolant ports 21904 for connecting to coolant hoses 21712,21714. An actuator 21902 may act to regulate an engagement of a payloadto an inspection surface. The drive module 21704 includes a motor 21706and wheel 21808.

Referring to FIGS. 60-61, alternate indirect drive modules 22000A,22000B are depicted. Drive module 22000A shows a motor 21706 positionedin front or behind the wheel 21708. Drive module 22000B shows a motor21706 positioned above a wheel 21708. The example indirect drive modules22000A, 22000B may be included with embodiments of the inspection robot21700 or other embodiments herein, and a given embodiment may includemore than one type of drive module (e.g., reference FIGS. 21-25, 28,30-31, 57-61, 81, 108-111, 114-115 for some drive module examples) on asame inspection robot. The presence of more than one type of drivemodule on an inspection robot may be at the same time—e.g., with a firstdrive module of a first type and a second drive module of a second typeboth mounted on the inspection robot body—or at distinct times, forexample with an inspection robot utilizing a first type of drive modulein a first configuration, and utilizing a second type of drive module ina second configuration. Distinct drive modules may be utilized tosupport distinct inspection packages (e.g., distinct payloads, sensortypes, and/or support differences such as electrical coupling, coolantand/or couplant provision, communication coupling, etc.), distinctinspection surfaces (e.g., inspection surface material, geometry,orientation, etc.), distinct power ratings, distinct inspection surfaceattachment forces, or the like. The utilization of modular drives (e.g.,using the drive modules) allows for rapid replacement and/or service ofdrive modules, rapid configuration of the inspection robot includingchanging of drive modules having different drive, interface, andinspection support characteristics, and convenient distribution andisolation of inspection robot capabilities, allowing for separatedevelopment and support of aspects of the inspection robot (e.g., drivemodules, inspection robot such as internal electrical, control, and/orcoolant management within the inspection robot housing, and/orpayloads—including sleds, payload support and attachment, and/or sensorconfigurations) with consistent and/or mutually configurable interfacesbetween the aspects of the inspection robot that allow the separatelydeveloped and/or supported aspects of the inspection robot to be readilycombined with zero or minimal design effort utilized to ensure that theseparately developed and/or supported aspects will function properly.

Without limitation to any other aspect of the present disclosure,example configuration operations for aspects of the inspection robotinclude operations such as: updating computer readable instructionsstored on a control board of the inspection robot; replacing a controlboard of the inspection robot; swapping out a sled of a payload;swapping out a sensor of a payload; swapping out a first payload for asecond payload; adjusting a coolant flow path through the inspectionrobot, a drive module, or other component; swapping out a drive module;changing a removeable interface plate; changing a calibration of acontrol board of the inspection robot; changing a data acquisition boardof the inspection robot; and/or adjusting a configuration (e.g., shape,mounting position, mounted sleds thereon, and/or mounted sensorsthereon) of a payload. The described configuration adjustments arenon-limiting examples, are not mutually exclusive, and in someembodiments one or more of the separately listed operations may be thesame operation (e.g., swapping a sensor of a payload, changing a controlboard that is the data acquisition board, etc.).

Without limitation to any other aspect of the present disclosure,example mutually configurable interfaces between aspects of theinspection robot include: an interface between a drive module and acontrol board (e.g., a peripheral board) of the inspection robot; aninterface between a payload and a drive module and/or between a payloadand a control board of the inspection robot; and/or an interface betweena peripheral device (e.g., a camera, a sensor positioned separately froma payload, and/or another device such as a data collector, actuator,encoder, or the like) and a control board of the inspection robot.Example and non-limiting interfaces include one or more of: a mechanicalcoupling interface, an electrical coupling interface, a communicationscoupling interface, and/or a coolant coupling interface. In certainembodiments, a removeable interface plate forms at least a portion ofthe interface and is configurable (e.g., having sufficient I/O capacityto support multiple device arrangements, and/or changeable betweendistinct plates to support multiple device arrangements) to support themutually configurable interfaces.

Referring to FIGS. 62-63, a center encoder 21718 is depicted. The centerencoder 21718 has a wheel 22202, an upper encoder limb 22206, and alower encoder limb 22208, the upper and lower encoder limbs 22206, 22208connected by an encoder joint 22204. The center encoder 21718 may beattached to the housing 21702 with an encoder connector 22210. Theencoder 21718 may be of any type as set forth throughout the presentdisclosure, including at least a contact encoder or a contactlessencoder, and may be optical, electromagnetic, mechanical, or any othertype of encoder.

Referring to FIG. 64, a drive module 22400 and details of wheel 21708are shown. The example drive module 22400 includes a gas spring 22402actuator and a mounted payload 22404. The example drive module 22400 maybe utilized, in whole or part, in embodiments throughout the presentdisclosure, and may include the mounted payload 22404 in addition to, oras an alternative to, a payload 22404 mounted directly on the robothousing. In certain embodiments, the mounted payload 22404 may bepositioned forward of the robot, behind the robot, or an inspectionrobot may include payload(s) both forward and behind the robot.

Referring to FIGS. 65-68, rail components 22500, 22600 of a modularpayload rail are shown including rail components 22502 and connectionjoints 22504. FIG. 66 shows the rail components 22500, 22600, combinedto form a straight payload rail 22700. FIG. 66 shows the rail components22500, 22600, combined to form a non-linear or curved payload rail22800. The example in FIGS. 65-68 depicts the rail having a number ofjoints that are coupled with a Hirth joint. The utilization of a Hirthjoint allows for rapid reconfiguration of the coupling between joints ata number of discrete angles, where the resolution between discretepositions is selectable according to the number and arrangement of teethon the Hirth joint. Accordingly, the geometric configuration of thepayload is rapidly adjustable to meet the needs of the system, forexample to follow the geometry of the inspection surface. Further, theHirth joint provides for a securing force to maintain the selectedconfiguration of the payload that the utilization of a Hirth joint isoptional and non-limiting, and any other payload arrangement and/orcoupling mechanism is contemplated herein.

Referring to FIGS. 69-71 show various aspects and exampled of aremoveable interface plate. FIG. 69 shows a partial view 22900 of aninspection robot with a removable interface plate 22902 attached to thehousing 21702. An example removable interface plate 22902 for changingpayload/sensor configurations may have multiple connections 22904 invarious configurations. FIGS. 70A-70B show gaskets 23000A, 23000B forsupporting different connection configurations. FIG. 71 shows an exampleremoveable interface plate 23100, 22902 for supporting different drivemodule configurations. The utilization of a removeable interface plate22902, where present, allows for rapid reconfiguration of the inspectionrobot, including a changing of I/O to support payloads, drive modules,communications, tether coupling, or the like. In certain embodiments, aremoveable interface plate 22902 coordinates with other features toenhance the configurability of the inspection robot. Without limitationto any other aspect of the present disclosure, example features tosupport rapid configurability include: swappable payloads; adjustablepayload arrangements; swappable control cards (e.g., reference FIGS.95-97); swappable drive modules; adjustable coolant flow configurations(including at design time and/or at run time); and/or modularizedcontrol elements including: control of inspection operations, drivemodules, motive operations, software/firmware updates, and/orcommunication controllers and/or data collection operations. Withoutlimitation to any other aspect of the present disclosure, featuresherein to support configurability provide for reduced inspectionoperation times, better configuration of the inspection robot hardwareand controls to the inspection environment, greater confidence that aninspection operation can be completed successfully, reduction indedicated resources to complete inspections for off-nominal conditions(e.g., reducing the number of parts, spares, and/or additionalinspection robots that need to be brought to a location, the ability toservice and/or change parts of the inspection robot on a location,and/or reduction of hotshot runs to get replacement parts and/oralternative versions of parts such as alternate drive modules and/orpayloads having different configurations), and/or a greater ability torespond to on-site conditions that are found to be different relative toestimated conditions (e.g., inspection surface shape, inspection surfacetemperature, geometry and/or position of obstacles, etc.). In certainembodiments, inspection costs are significantly reduced, for example dueto expensive components (e.g., the inspection robot body and relatedcomponents) being adaptable for multiple environments, allowing forservicing of multiple surfaces with just a few more affordablecomponents (e.g., maintaining a few versions of the drive modules,rather than a few separately configured inspection robots), reducingon-site time for service and/or configuration of the inspection robot,and/or reducing expensive trips to a service and/or manufacturingfacility at the time of inspection operations. Overall, embodimentsherein improve the inspection operations, including without limitation:ensuring that the inspection robot is configured correctly; adjustingthe configuration of the inspection robot on-site, with limited toolsand/or service facilities; rapid replacement of parts, sensors,payloads, drive modules, etc.; and/or rapid on-site response tounexpected conditions or events.

Referring to FIGS. 72-74, different aspects of the housing 21702 areshown. FIG. 72 depicts an interior view 23200 of the housing 21702. Theexample of FIG. 72 depicts interfaces for cooling, mounting of externalhardware and/or internal components, and/or interfaces for payloads,tether, removeable interface plates, or the like. FIGS. 73-74 show a tophousing component 23300 and a bottom housing component 23400. Theexample top housing component 233300 covers the inspection robotinterior, protecting from debris, impacts, intrusion of water, or thelike. In certain embodiments, the top housing component 23300 may be atransparent material, for example allowing visual verification of properinstallation of components within, and/or visibility to lights orindicators, for example provided on one or more control cards within theinspection robot. In certain embodiments, the top housing component23300 includes light(s), a readable screen, or other component thereonallowing the inspection robot to display information (e.g., status,direction of travel, speed of travel, inspection state or stage, etc.)that is visible to the operator. The example bottom housing component23400 includes a configured bottom that provides a reservoir to retainselected cooling fluid (e.g., couplant emitted by UT sensors, that flowsdown the inspection surface into the reservoir) and provides thermalcontact to selected portions of the inspection robot body. The examplebottom housing component 23400 thereby provides for cooling of selectedinternal components, using direct thermal contact with those components,and/or thermal contact with a high conductivity path (e.g., a heat sinkor conduit that is thermally coupled to components within the inspectionrobot). In the example of FIG. 74, the reservoir is formed when theinspection robot is positioned on the inspection surface, with thereservoir defined between the inspection surface and the inspectionrobot body, with raised ridges—which may be attached to the bottomhousing component 23400 and/or formed integrally therewith—defining theshape and depth of the reservoir, as well as the contact locations onthe bottom of the inspection robot. The configuration of the reservoir,where present, may cooperate with the position of internal components(e.g., heat sinks, conductive paths, temperature generating components,etc.) of the inspection robot for thermal management.

Referring to FIG. 75, a rear perspective view of an inspection robot21700 is shown. The example of FIG. 75 depicts a number of aspectsdescribed throughout the present disclosure in an example arrangementfor illustration. The example of FIG. 75 depicts drive modules havingwheels positioned under the body of the inspection robot, reducing thewidth of the inspection robot assembly. The example of FIG. 75 depictsdirect data and power connections 21716 (cables as shown) between eachdrive module and the body of the inspection robot. The example of FIG.75 further depicts coolant/couplant flowing through the drive modulesand then to the payloads. The example of FIG. 76 depicts the coolantflowing from a water source (e.g., industrial water supply, municipalwater supply, dedicated stored water for the inspection, etc.) to a basestation—for example a pump and/or water storage coupled to theinspection robot (e.g., through the tether) and operable to providecouplant/coolant to the inspection robot during inspection operations.The example of FIG. 76 further includes the coolant flowing through theinspection robot body, which may be configured to thermally couple thecoolant with a control board of the inspection robot (e.g., amodular/removeable board, a main control board, and/or a dataacquisition board). In the example of FIG. 76, the coolant flows throughthe drive module(s) on each side, and then to the payload and/or sensor.In certain embodiments, the coolant further progresses to the inspectionsurface, and is collected, at least in part and for a residence period,into a reservoir formed between the inspection robot and the inspectionsurface, promoting further heat transfer from selected componentsthrough thermal contact with the reservoir. The order, arrangement, andselection of components for thermal contact with the coolant as depictedin FIG. 76 is a non-limiting arrangement, and components in the flowpath may be omitted or rearranged, and other components not shown inFIG. 76 may be positioned in the flow path.

Referring to FIG. 76, a flow chart schematic 23600 depicts an examplecoolant flow path for an inspection robot 21700. The example of FIG. 76depicts the coolant flowing from a water source (e.g., industrial watersupply, municipal water supply, dedicated stored water for theinspection, etc.) to a base station—for example a pump and/or waterstorage coupled to the inspection robot (e.g., through the tether) andoperable to provide couplant/coolant to the inspection robot duringinspection operations. The example of FIG. 76 further includes thecoolant flowing through the inspection robot body, which may beconfigured to thermally couple the coolant with a control board of theinspection robot (e.g., a modular/removeable board, a main controlboard, and/or a data acquisition board). In the example of FIG. 76, thecoolant flows through the drive module(s) on each side, and then to thepayload and/or sensor. In certain embodiments, the coolant furtherprogresses to the inspection surface, and is collected, at least in partand for a residence period, into a reservoir formed between theinspection robot and the inspection surface, promoting further heattransfer from selected components through thermal contact with thereservoir. The order, arrangement, and selection of components forthermal contact with the coolant as depicted in FIG. 76 is anon-limiting arrangement, and components in the flow path may be omittedor rearranged, and other components not shown in FIG. 76 may bepositioned in the flow path.

Referring to FIG. 77, a control schematic 23700 is shown. The examplearrangement of FIG. 77 schematically depicts control componentsdistributed within and/or around the inspection robot. In certainembodiments, control boards (e.g., LOCALIZATION, EXPANSION, BRAIN, etc.)may be replaceable, for example by removing a top cover and swapping outa plugged in printed circuit board (PCB). The swapping availabilityallows for rapid reconfiguration of the inspection robot, for example tomanage distinct payloads, peripherals (e.g., cameras), perform a rapidupdate of control algorithms, and/or to replace a failed or faultedboard. In the example of FIG. 77, each drive module includes a separatecontrol board for the drive module, which may communicate status and/orrespond to commands to the drive module to control operations of thedrive module and/or attached devices (e.g., an encoder, mounted payload,etc.). In certain embodiments, the payload is mounted on a drive module,but is electrically coupled to the inspection robot body separately fromthe drive module. In certain embodiments, a peripherals board isprovided that interfaces with attached peripherals and/or the drivemodule, isolating control operations for the peripherals and allowingfor a change in peripherals to have control support isolated to theperipherals board, allowing for support of any given peripheral deviceand/or drive module to be limited to swapping or updating theperipherals board. While the peripherals board allows for rapid swappingof support for the peripherals, a given peripherals board may supportmore than one type of peripheral device and/or drive module, allowingfor the change of peripheral devices to be made without swapping theperipherals board for at least certain devices.

Referring to FIG. 78, a side view 23800 of an inspection robot 21700 isshown. The drive modules 21704A, 21704B, on a common side of the housing21702 are operative linked such that they can pivot relative to oneanother around an axis at an angle relative to the direction of travel.The linkage between drive modules allows for the articulation of thedrive module wheels in a controlled manner, enhancing the ability of theinspection robot to traverse obstacles and/or minor surface featureswhile maintaining contact with the inspection surface. The viewsdepicted in FIGS. 78-81 are consistent with an example arrangement ofthe inspection robot, and depict a mutually consistent embodiment of theinspection robot.

Referring to FIG. 79, a partial front view 23900 of an inspection robotmay be seen. There may be a drive module linking suspension 23902 thatcan operationally link drive modules 21704A, 21704C on different sidesof the housing 21702.

Referring to FIG. 80, a drive module linking suspension 23902 isdepicted. There may be a central pivot 24002 enabling drive modules21704 on opposing sides of the housing 21702 to move up and downrelative to one another. The drive module linking suspension includes ahousing attachment mechanism 24404 and a drive module attachmentmechanism 24406.

Referring to FIG. 81, a bottom view of the inspection robot 21700 may beseen with the module linking suspension 23902.

Referencing FIG. 82, an example inspection robot 24100 is depictedschematically. The configuration of the example robot 24100, includingarrangements of payloads, components, sensors, electronic boards, andthe like, is a non-limiting example provided to illustrate certainarrangements and capabilities of an inspection robot 24100. Any otherarrangements, components, or the like as set forth throughout thepresent disclosure may be utilized, in whole or part, with an inspectionrobot 24100, either in addition to, or as a full or partial replacementfor, aspects depicted in FIG. 82. The example inspection robot 24100includes a payload 24102 mounted to a housing 24118 of the inspectionrobot 24100. The example of FIG. 82 depicts the payload(s) 24102 mounteddirectly to drive modules 24108, which are mechanically coupled to theinspection robot 24100. In certain embodiments, the payload(s) 24102 maybe mounted directly to the housing 24118, such as on a forward railattached the housing 24118. Alternatively, as depicted in FIG. 82, thepayload(s) 24102 may be mounted to the housing 24118 indirectly, such asvia the drive module(s) 24108. In certain embodiments, one or morepayloads may be mounted directly to the housing, and one or more otherpayloads may be indirectly mounted to the housing—for example withforward payloads mounted to the drive modules, and rearward payloads(not shown) mounted to a rail, mount point, or other configurationdirectly to the housing.

The example inspection robot 24100 includes the housing 24118 havingremoveable interface plate(s), for example with a forward removeableinterface plate 24124, a rearward removeable interface plate 24120, andside removeable interface plates 24122, 24126. The example removeableinterface plates 24120, 24122, 24124, 24126 are a non-limiting exampleof the number and positions of removeable interface plates that may bepresent. The example removeable interface plates 24120, 24122, 24124,24126 are coupled to a target component on a first side of theremoveable interface plate (e.g., to the drive module 24108 and/orpayload 24102 in the example of FIG. 82), and coupled to an electronicboard 24112, 24114, 24116 on a second side of the removeable interfaceplate. The example of FIG. 77 includes a first electronic board 24112coupled to the removeable interface plate 24124 and the payloads 24102,a second electronic board 24114 coupled to the removeable interfaceplates 24122, 24126 and the drive modules 24108, and a third electronicboard 24114 coupled to the removeable interface plate 24120, which isunused in the example of FIG. 82. The number and arrangement ofelectronic boards coupled to removeable interface plates is anon-limiting illustration. The electronic boards include an electricalcommunication configuration that is compatible with the coupledcomponent(s), for example the payload(s) and/or drive module(s).Accordingly, the selection of the electronic board(s) may depend uponthe electrical requirements of the coupled components (e.g., grounding,A/D processing, voltages, sensing requirements such as current sensing,etc.), the number and type of electrical interfaces (e.g., the number ofI/O pins and/or the types of these), processing requirements to managecomponent communications (e.g., post-processing of sensor data,communication rates, etc.) and the available resources for a givenelectronic board (e.g., processing resources, communication resources,and/or memory resources). Accordingly, a given electronic board maysupport multiple components and be coupled to more than one interface(e.g., electronic board 24114 coupled to both removeable interfaceplates 24122, 24126) and/or components (e.g., electronic board 24114coupled to both drive modules 24108, and/or electronic board 24112coupled to both payloads 24102). In certain embodiments, for examplerelating to a payload 24102 having numerous high demand sensors 24106,more than one electronic board 24112, 24114, 24116 may be provided tosupport a given removeable interface plate 24120, 24122, 24124, 24126and/or component of the inspection robot 24100. In the example of FIG.82, the sensors 24106 are mounted on a rail 24104 of the payload 24102,and may further be mounted on sleds (not shown) or other devicesconfigured to position the sensors 24106 to engage an inspection surfacewhen the inspection robot 24100 is positioned on the inspection surface.Any configuration of a sensor 24106, rail 24104 or other sensor mountingmechanism, and/or payload 24102 as set forth in the present disclosureis contemplated herein. The electronic boards 24112, 24114, 24116, 24128may each include, be formed of, and/or be positioned on a printedcircuit board (PCB).

The payload(s) 24102 may have sensors 24106 mounted thereon, for examplein any arrangement as set forth throughout the present disclosure. Thesensors 24106 may be of any type, for example an ultrasonic (UT) sensor,an electromagnetic sensor of any type, a temperature sensor, adensitometer, a vibration sensor, an imaging sensor (e.g., a camera)which may be responsive in the visual spectrum or beyond the visualspectrum, and/or a pressure sensor. The sensor examples are non-limitingfor purposes of illustration.

In certain embodiments, the components (e.g., payloads 24102 and/ordrive modules 24108) are coupled through the removeable interface plates24120, 24122, 24124, 24126, but may have additional coupling and/orsupport through other interfaces. For example and without limitation,mechanical coupling of the drive modules 24108 may be separate from theelectrical coupling through the removeable interface plates 24120,24122, 24124, 24126, or the electrical and/or mechanical coupling may becombined with the electrical coupling. In another example, couplantconnections may be provided separately from the removeable interfaceplates 24120, 24122, 24124, 24126. For example, a couplant connectionbetween the housing 24118 and the drive modules 24108 may be separatefrom the electrical and/or mechanical connections, such as depictedelsewhere in the present disclosure. Where the payloads 24102 includessensors 24106 utilizing a couplant (e.g., as a part of the sensingoperations, such as in a UT sensor, and/or for another reason such asproviding cooling operations for the sensor 24106), the couplant may beprovided to the payload 24102 from the housing (separate from theremoveable interface plate), from the housing via the removeableinterface plate, and/or from another component such as the drive module24108.

The removable interface plates 24120, 24122, 24124, 24126 include anelectrical coupling interface compatible with the component (e.g.,payload 24102 and/or drive module 24108), including at least a numberand type of connections, connector types, supporting electricalcharacteristics (e.g., component specifications of the removeableinterface plate materials and connections, isolation, ground, EMIresponse, voltage rating, current rating, etc.), and/or supportingphysical configuration (e.g., compatible material types; materialshaving appropriate resistance to vibration, temperature, and/orchemicals in the target environment; appropriate spacing and headroomfor connectors, cable routing, etc.). An example removeable interfaceplate 24120, 24122, 24124, 24126 includes a high temperature plastic,for example as set forth throughout the present disclosure. An exampleremoveable interface plate 24120, 24122, 24124, 24126 is coupled to thehousing using a quick connect coupling, for example a couplingconfigured for operation without tools (e.g., a levered coupling, ascrew with an enhanced diameter capable of operation without tools,etc.), and/or for operation with simple readily available tools (e.g., ahex wrench, screwdriver, etc.).

The utilization of removeable interface plates 24120, 24122, 24124,24126 provides for a highly flexible configuration of the inspectionrobot, for example allowing an operator to readily swap payloads havinga different sensing package and/or physical geometry of sensors,swapping drive modules having distinct characteristics (e.g., powercapability, magnetic coupling force, mount types and/or mount positions,geometry arrangements of a motor and/or wheel), and/or replacingcomponents that are degraded and/or failed. Additionally, theutilization of removeable interface plates 24120, 24122, 24124, 24126allows for responsiveness in challenging environments, for exampleenvironments having high heat, vibration, enclosed spaces, and/orchemical exposure, where the conditions promote higher failure rates ofcomponents, and the inspection environments tend to be distant fromavailable service facilities. Further, the challenges of theenvironments, for example with challenging conditions promotingdegradation of facilities (e.g., a pipe wall that is a part of theinspection surface), combined with high uncertainty prior to inspection(e.g., with significant time passing between inspections, first-timeinspections of a surface, and/or inspection of a surface that is in alow visibility area), provide challenges due to the likelihood thatinspection conditions of the inspection surface are different from theestimated conditions when the inspection was planned. The highflexibility provided by the removable interface plates 24120, 24122,24124, 24126, as well as other aspects of the present disclosure,greatly enhance the ability to manage these challenges, allowing theoperator to rapidly configure the inspection robot 24100 for the actualconditions, and to respond to unexpected conditions found during theinspection.

An example electronic board 24112 includes an electrical processingconfiguration compatible with the payload 24102. For example, theelectronic board 24112 may include communication resources sufficient tosample data from the sensor(s) 24106 at scheduled data rates, to performlow level processing such as A/D processing, filtering, de-bouncing, orthe like, and/or processing and/or memory resources to perform plannedprocessing of the sensor data, for example performing primary and/orsecondary mode analysis of UT sensor data. In certain embodiments, theelectronic board 24112 passes raw data to another component of thesystem, such as a data acquisition circuit, an external device, or thelike. In certain embodiments, the electronic board 24112 provides somelevel of processing to the sensor data, and passes the processed data toanother component of the system. In certain embodiments, the electronicboard 24112 does a combination of these, for example processing data(e.g., for preliminary analysis, confirmation of inspection operations,confirmation that calibration settings are correct, etc.) while passingalong the raw data (e.g., to allow deeper analysis on a more capablesystem, post-processing analysis, etc.), and/or a combination of these(e.g., processing some or all of the data, and passing along some or allof the raw data).

An example electronic board 24112 includes a dedicated board having apayload specific configuration, for example having an A/D processingconfiguration, a selected communication definition (e.g., samplingrates, data types, bit depth, etc.), a selected pre-processingdefinition (e.g., operations and/or characteristics of processingoperations to be performed before data is passed along to anothercomponent), a selected payload identification definition (e.g., payloadtypes supported, payload versions supported, including hardwareversions, sensor versions, software versions related to the payload,and/or a unique identifier for the payload—for example allowing theelectronic board to ensure that the coupled payload is compatible withthe board, including electrically compatible, algorithmicallycompatible, and/or physically compatible), and/or a selected payloaddiagnostic definition (e.g., confirming that planned or requireddiagnostics are available, that specific diagnostic algorithms are beingperformed, that a diagnostic version is up-to-date or sufficient, and/orensuring that a diagnostic is available for specified components). Theexample electronic board 24112 is further releasably mounted to a mainboard 24128 positioned within the housing. Releasably mounted to themain board 24128 includes direct mounting to the main board 24128, forexample engaging a slot of the main board, a dedicated interface builtonto the main board to engage the electronic board 24112, or the like.Additionally or alternatively, mounted to the main board 24128 caninclude interfacing through an intermediate board, bus, or the like (notshown), for example coupling to an intermediate board that is coupled tothe main board 24128, where the intermediate board supports a range ofavailable electronic boards 24112.

The utilization of a dedicated electronic board 24112 allows for thesupport of highly complex payloads 24102 and/or drive modules 24108,which can require significant customization to support a high number ofsensors that provide specialized and high rate data, while maintainingthe flexibility of the inspection robot 24100 by providing a convenientpackage of support that can be removed or replaced without interferingwith the rest of the inspection robot 24100 system. In certainembodiments, a dedicated electronic board 24112 is one that supports aspecific component (e.g., a single, unique payload) and/or a class ofcomponents (e.g., a group of equivalent or similar payloads, such aswith matching sensor arrangements and/or software, with closely relatedsensor arrangements and/or software, etc.).

In certain embodiments, swapping a payload and/or drive module(“component swap”) herein includes performing the component swap withoutchanging the removeable interface plate and/or electronic board, wherethe removeable interface plate and/or electronic board are compatiblewith the swapped component. In certain embodiments, performing thecomponent swap includes changing the removeable interface plate withoutchanging the electronic board. In certain embodiments, performing thecomponent swap includes changing the electronic board without changingthe removeable interface plate. In certain embodiments, performing thecomponent swap includes changing the electronic board and the removeableinterface plate. In certain embodiments, a change to the electronicboard includes performing one or more of: changing a calibration on theelectronic board (e.g., writeable parameters to configure operations ofthe electronic board, which are generally below the level of a versionupdate to control operations); changing an algorithm version on theelectronic board (e.g., updating instructions stored in a computerreadable medium on the controller, for example as a version updateand/or alternate algorithm according to the characteristics of theswapped component); and/or physically swapping out the electronic board(e.g., disengaging the electronic board from the main board, andinserting a different electronic board, such as a dedicated board forthe swapped component).

The example inspection robot 24100 includes a tether 24110, for exampleproviding power, communications, couplant, etc. from a base station (notshown), for example attended by an operator performing inspectionoperations. The presence of the tether 24110, and the composition of thetether 24110, are a non-limiting example for purposes of illustration.The tether 24110 may have any characteristics as set forth throughoutthe present disclosure.

Referencing FIG. 82, an example electronic board 24112 is depicted,having a number of circuits configured to functionally executeoperations of the electronic board 24112. The electronic board 24112 isdepicted for illustration, but the example of FIG. 86 is applicable toany electronic board (e.g., 24112, 24114, 24116, and/or main board24128), controller, circuit, etc. as set forth herein. The exampleelectronic board 24112 includes a payload interface circuit 24202 thatinterprets payload signals 24210 from the payload—for example fromsensors of the payload and/or other active components of the payload,and further in response to the payload specific configuration 24212(e.g., specifying information about how the payload signals 24210 are tobe processed, interpreted, sampled, etc.). The example electronic board24112 further includes a data distribution circuit 24204 thatcommunicates data values 24214 representative of data collected from thesensor(s) 24106 to an external device 24208 in response to the payloadsignals 24210. The data values 24214 may include one or more of: rawdata (e.g., direct information supplied by the sensor 24106, such asvoltages, current values, temperatures, etc.); sensor-processed data(e.g., low level determinations made by the sensor, such as atemperature, indicated wall thickness, response time value, etc.);diagnostic and/or fault code data; and/or status data (e.g., ON/OFF,operational state, etc.). An external device 24208, as used herein,references any one or more of: a device external to the inspection robot24100, and/or a device external to a system including the inspectionrobot 24100, a device external to the electronic board 24112. Exampleand non-limiting external devices 24208 include one or more of: thetether 24110 (e.g., communicatively coupled to a further device, such asa base station computer); a computing device communicatively coupled tothe inspection robot 24100 (e.g., a base station computer; a facilitycomputer such as one associated with an industrial system including theinspection surface; a mobile device such as an operator's mobile phoneor tablet; a wirelessly connected device; a cloud server and/orcomputing device; a web portal; and/or a cloud application). In certainembodiments, the communications of the data distribution circuit 24204are responsive to the payload specific configuration 24212, for exampledefining processing to be performed to determine the data values 24214,communication rates, buffering information, etc.

An example electronic board 24112 further includes a payload statuscircuit 24206 that provides a payload identification value 24216 inresponse to the payload specific configuration 24212 and/or in responseto the payload signals 24210. The payload identification value 24216provides for a determination of which payload is presently on theinspection robot 24100, which sensors are mounted thereon, whichversions of control algorithms are installed, which versions ofdiagnostic algorithms are installed, and the like. In certainembodiments, the payload identification value 24216 identifies thepayload uniquely—for example the specific hardware component that isinstalled. In certain embodiments, the payload identification value24216 identifies the payload by functional equivalence, for examplesensors and/or supporting algorithms that provide a given capability,and that define processing, diagnostics, data labeling, data formatting,and the like. In certain embodiments, the payload identification value24216 identifies the payload at a high level, for example a payloadhaving imaging capability, UT sensing, EMI sensing, laser profiling, orthe like. The content of the payload identification value 24216 may varywith the purpose of the identification, including for example: where theidentification is used for informal operator support (e.g., ensuring thecorrect configuration of the inspection robot 24100); to meet aninspection certification requirement (e.g., providing object evidencethat the inspection was performed properly, with proper algorithmversions, diagnostic versions, sensor versions, calibration versions,etc.); to support iterative improvement operations (e.g., supportingpost-analysis to determine which sensor configurations have providedsuperior inspection results, to diagnose problems determined later inthe data and/or from practical experience following inspections, etc.);and/or to track utilization of specific components (e.g., totaloperating time for a particular sensor, linking incidents to specificcomponents such as components that have experienced a high temperature,collision with an obstacle, etc.). In certain embodiments, a payloadidentification value 24216 includes one or more of: a unique payloadidentifier, a payload calibration value, and/or a payload type value. Incertain embodiments, a component identification value includes one ormore of: a unique component identifier, a component calibration value,and/or a component type value. In certain embodiments, for example wherethe component is a sensor, an example component identification valueincludes one or more of: a unique sensor identifier, a sensorcalibration value, and/or a sensor type value.

The example of FIG. 83 is provided in the context of a payloadidentification value 24216 for clarity of illustration. Additionally oralternatively, any component of the inspection robot may be identified,including unique, functional equivalence, and/or high levelidentification. In certain embodiments, a payload identification value24216 may be referenced herein as a component identification value.Example and non-limiting components where an identification value may bedetermined include at least one or more of, without limitation: a drivemodule identification value; a drive motor identification value; asensor associated with any other component (e.g., a drive module,encoder, housing, couplant flow path, payload hardware, electricalconnectors, actuators, the tether, a data acquisition circuit, anelectronic board, a sled of the payload, and/or a wheel of the drivemodule, etc.). The identification operations of the electronic board24112 may be performed by any circuit, controller, board, or the like asdescribed throughout the present disclosure, and may be performed inrelation to any component of an inspection robot 24100 and/or systemincluding an inspection robot 24100.

With further reference to FIG. 82, an example inspection robot 24100includes a housing 24118, defining an interface opening (e.g., whereremoveable interface plate 24124 is engaged), the housing including amount (and/or a drive module coupled to the housing including the mount24130). The example system includes a first payload 24102 having asensor 24106 mounted thereon, where the first payload is configured toselectively couple to the mount 24130. The example system includes asecond payload 24102 having a sensor 24106 mounted thereon, where thesecond payload is configured to selectively couple to the mount 24130.The first and second payloads may be payloads with different sensorpackages, arrangements of the sensors on the payloads, and/or payloadswith distinct characteristics (e.g., sled shapes, sled materials, shapedfor different inspection surface shapes, etc.). In certain embodiments,the first and second payloads are functionally equivalent, for examplewith one of the payloads serving as a backup payload, for example in theevent of a failure of the first payload. The example system includes afirst removeable interface plate 24124 configured to mount over theinterface opening of the housing 24118, the first removeable interfaceplate 24124 having an I/O interface (e.g., connections, pin arrangementsand/or pin types, grounding, isolation, etc. as set forth throughout thepresent disclosure) compatible with the first payload on a first side,and a first electrical interface on a second side (e.g., compatible tocouple with an electronic board 24112). The example system includes asecond removeable interface plate 24124 configured to mount over theinterface opening of the housing 24118, the second removeable interfaceplate 24124 having an I/O interface compatible with the second payloadon a first side, and a second electrical interface on a second side(e.g., compatible to couple with an electronic board 24112). The firstelectrical interface and the second electrical interface may be the sameor distinct (e.g., a single board 24112 that is compatible with, and/orconfigurable to be compatible with, both the first payload and thesecond payload, where the payloads can be swapped without changing thephysical board, and/or where separate boards 24112 are used forcorresponding payloads). An example system includes an electronic board24112 compatible with both of the first electrical interface and thesecond electrical interface. An example system includes the electronicboard 24112 (or boards) configured to mount on a payload supportlocation of the main board 24128—for example at a location associatedwith the opening dedicated for payload support, at a location of themain board dedicated for payload support, on a slot provided for apayload board, etc.).

An example electronic board 24112 includes a payload interface circuit24202 that interprets signals from the first payload in response to afirst payload specific configuration, and that interprets signals fromthe second payload in response to a second payload specificconfiguration. In certain embodiments, multiple payload specificconfigurations are stored on the board 24112 (and/or otherwiseaccessible to the payload interface circuit 24202), and the payloadinterface circuit 24202 utilizes an identification of the payload todetermine which payload specific configuration to utilize forinterpreting signals from the payload. In certain embodiments, thepayload specific configuration for the payload is installed on the board(or other accessible area to the payload interface circuit 24202) whenthe payload is swapped, and the payload interface circuit 24202 eitherutilizes the installed payload specific configuration, and/or utilizesan identification of the payload to confirm that an installed payloadspecific configuration is a correct one.

Referencing FIG. 84, an example procedure 24300 for rapid configurationof an inspection robot is schematically depicted. The example procedure24300 includes an operation 24302 to swap a first payload of aninspection robot to a second payload of the inspection robot. The firstpayload includes a first sensor package, and the second payload includesa second sensor package that is distinct in some aspect from the firstsensor package. Example distinctions include one or more of: differentsensor types; a different sensor count; a different electrical interfaceto the sensors; a different couplant requirement for the sensors; and/ora different calibration value for the sensors. The example procedure24300 further includes an operation 24304 to swap a first removeableinterface plate mounted on a housing of the inspection robot over anopening, to a second removeable interface plate mounted on the housingof the inspection robot over the opening. The first removeable interfaceplate includes an I/O interface compatible with the first payload, andthe second removeable interface plate includes an I/O interfacecompatible with the second payload. In the example procedure, theremoveable interface plate is swapped, providing for a rapid changebetween payloads having different electrical interface requirements(e.g., number of cables, type of connectors, different electricalcharacteristics for the electrical coupling, etc.). In certainembodiments, the removeable interface plate is not swapped, for examplewhere a single interface plate is compatible with both payloads. Incertain embodiments, the payloads are functionally identical—for examplehaving the same number of sensors, sensory types, and/or sensorcalibrations. In certain embodiments, the swap may be performed inresponse to a fault condition for a sensor, a mechanical failure to apayload (e.g., a failed sled, coupling arm, damaged component, etc.), toconfirm that inspection data is correct (e.g., testing at last a sectionof the inspection surface with another similar sensor package), and/orto manage wear of components (e.g., to limit utilization of a payload,and/or to even out utilization between payloads).

An example procedure 24300 further includes an operation 24308 to updatea first payload specific configuration of a payload interface circuit toa second payload specific configuration, for example where the first andsecond payloads utilize distinct payload specific configurations. Thepayload specific configurations, without limitation to any other aspectof the present disclosure, include an electrical interface descriptionfor each corresponding payload. An example procedure 24300 furtherincludes an operation 24310 to swap a first electronic board, compatiblewith a first electrical interface of the first payload, to a secondelectronic board, compatible with a second electrical interface of thesecond payload. The example procedure 24300 further includes anoperation 24306 to operate the inspection robot to interrogate at leasta portion of the inspection surface with the second payload.

Referencing FIG. 85, an example inspection robot 24400 includes ahousing 24118, a payload interface (e.g., openings and/or removeableinterface plates 24124, 24120), a tether interface 24405, and a drivemodule interface (e.g., openings and/or removeable interface plates24122, 24126). The example of FIG. 84 describes certain openings and/orremoveable interface plates as associated with the payload, tether,and/or drive modules for clarity of the description. However, in certainembodiments any opening and/or removeable interface plate can beutilized for any one of the components of the inspection robot 24400.The payload interface, tether interface, and/or drive module interfacemay be defined upon installation of the appropriate components, and/ordefined within the housing—for example coupling a payload electronicboard to the removeable interface plate where the payload iselectrically coupled, and/or coupling a drive module electronic board tothe removeable interface plate where the drive module is electricallycoupled. In the example of FIG. 84, electronic board 24112 services thepayload interface, electronic board 24116 services the rearwardremoveable interface plate (e.g., where a second payload and/or payloadsmay be mounted), and the electronic board 24114 services two drivemodules, one on each side of the inspection robot 24400 in the example(e.g., reference FIG. 82). In the example of FIG. 84, the electronicboard 24402 may be an open slot, for example to be utilized when theconfiguration of the inspection robot 24400 requires an additionalboard, a board dedicated to servicing the tether interface 24405, or anextra board utilized to allow the utilization of additional payload(s)without installing a board—for example where the electronic board 24112is configured to service a first type of payload, and the additionalboard 24402 is configured to service a second type of payload. Thecoupling between boards 24112, 24114, 24116 is a non-limiting example.In a given embodiment, any board 24112, 24114, 24116 may service anyelectrical interface, and in certain embodiments the electrical couplingbetween boards 24112, 24114, 24116 and interfaces may be configurable(e.g., utilizing solid state switches or any other re-configurationarrangement). In certain embodiments, the tether interface 24405 isserviced by a main board 24128, or another board (not shown) that may beremoveable or not.

In certain embodiments, a first electronic board (e.g., board 24402, themain board 24128, a tether dedicated board, or a board wirelesslyconnected to a base station and/or a computing device remote from therobot) includes a primary functionality circuit communicatively coupledto a base station through either a tether interface 24405 or coupledwirelessly to the base station or computing device remote from therobot. The example primary functionality circuit performs operationssuch as: communication operations with the base station; receives andconfigures (and/or instructs the configuration) power from the basestation (e.g., providing a selected voltage to components of theinspection robot, converting power between AC/DC, and/or confirming thatpower coupling is properly connected), if the board is connected bytether to the base station; sends data to the base station; receivesinstructions from the base station; and/or provides couplant relatedcommunications (e.g., requesting flow rates, turning on or off couplantflow, and/or receiving couplant information such as temperature,composition, etc.). In certain embodiments, the primary functionalitycircuit performs operations to update calibrations, algorithms (e.g.,control and/or diagnostic algorithms), firmware, or the like for variousboards, circuits, sensors, and/or actuators throughout the inspectionrobot 24400. The described operations of the primary functionalitycircuit are a non-limiting example.

In certain embodiments, a second electronic board (e.g., board 24112) isoperationally coupled to the payload interface, where the secondelectronic board includes a payload functionality circuit that iscommunicatively coupled to a selected payload through the payloadinterface. Example operations of the payload functionality circuitinclude operations such as: confirming the presence and/oridentification of the payload; providing commands to the payload;receiving data from the payload; and/or configuring and/or processingelectrical signals from the payload. The described operations of thepayload functionality circuit are a non-limiting example.

In certain embodiments, a third electronic board (e.g., board 24114)includes a drive module functionality circuit communicatively coupled toa selected drive module through the drive module interface. In theexample of FIG. 84, a single board 24114 is capable to operate bothdrive modules. In certain embodiments, each drive module may becontrolled by a single board, but additionally or alternatively a boardmay be configured to operate any number of drive modules. Exampleoperations of the drive module functionality circuit include operationssuch as: providing drive commands to the drive module(s); receivingstatus information from the drive module(s) (e.g., diagnostics, statusvalues, rotational counts of a motor, temperature feedback, positionfeedback, etc.); providing couplant flow commands to the drive module(s)(e.g., where couplant is passed through the drive module as a part of acooling circuit, where flow rates and/or flow paths are controllable atleast in part through actuators such as valves, controllablerestrictions, or the like); and/or providing any other commands orreceiving any other data from the drive module(s). The describedoperations of the drive module functionality circuit are a non-limitingexample.

In the example of FIG. 84, the boards 24112, 24116, 24402, 24114 arecoupled to the main board 24128 through a slot coupling, allowing for aquick connect and disconnect from the main board 24128. Referencing FIG.85, additionally or alternatively one or more of the boards 24112,24116, 24402, 24114 are coupled to the main board 24128 through anintermediate coupling PCB 24502. The utilization of an intermediatecoupling PCB 24502 allows for quick connection of the boards 24112,24116, 24402, 24114 with a lower likelihood of disturbing the main board24128, and further allows for the intermediate coupling PCB 24502 tohave mechanical support dedicated to improve the robustness of theintermediate coupling PCB 24502 to the forces introduced with couplingand decoupling the boards 24112, 24116, 24402, 24114, improving thereliability of the inspection robot 24400 where board changes areperformed in less than ideal conditions, such as those which may beexperienced in the field at a facility having the inspection surface. Incertain embodiments, some boards 24112, 24116, 24402, 24114 may becoupled directly to the main board 24128, while other boards 24112,24116, 24402, 24114 may be coupled to an intermediate coupling PCB24502. For example, boards that are more likely to be frequently changedout (e.g., payload boards) may be coupled to an intermediate couplingPCB 24502, while other boards that are more likely to be retained forextended periods (e.g., a drive module board and/or a tether board) maybe coupled to the main board 24128. The connection of the boards 24112,24116, 24402, 24114 to the interfaces (e.g., payload, drive module,tether, etc.) are omitted in FIG. 85 for clarity of the depiction.

An example inspection robot 24400 includes a payload board (e.g., 24112)having a first payload interface circuit, and another board (e.g., aseparate board associated with a second payload) having a second payloadinterface circuit, where the inspection robot 24400 utilizes a firstpayload in response to the first payload interface circuit mounted inthe housing (e.g., where board 24112 is mounted in the housing), andutilizes a second payload in response to the second payload interfacecircuit mounted in the housing (e.g., where the separate boardassociated with the second payload). The example configuration allowsfor automatically changing inspection operations in response to apayload swap, for example where the boards are swapped with the payload.Additionally or alternatively, the example configuration allows forswitching which payload is utilized, for example where both payloads aremounted on the inspection robot, where a swap of the boards (e.g., fromthe payload board to the separate board) automatically changesinspection operations from the other payload. In the example, the secondpayload interface circuit is described on a separate board. In certainembodiments, the second payload interface circuit may be embodied, atleast in part, as computer readable instructions stored on a computerreadable medium, where positioning the second payload interface circuiton the inspection robot may be performed by adding or replacinginstructions on the payload board, for example by adding or over-writinginstructions positioned on the payload board with instructionsimplementing the second payload interface circuit.

An example inspection robot 24400, 24500 includes a generalized payloadcoupling circuit, for example where slots of the main board 24128 and/orthe intermediate coupling PCB 24502 are configured for receiving apayload board. For example, boards to support payloads may have distinctcharacteristics (e.g., I/O requirements, power regulation, types of I/Osuch as frequency inputs, current inputs, voltage inputs, etc.) relativeto other board types (e.g., drive boards and/or drive module boards,tether boards, etc.). The utilization of generalized slots of particulartypes, including payload types, may provide for greater efficiency(e.g., lower overall board support component requirements, reducedalgorithmic support for I/O flexibility, etc.), and/or allow for greaterflexibility (e.g., limiting support for certain slots to payload typesmay allow for accommodating a greater range of payload types relative toa slot configured to accept any type of board coupled to the slot). Incertain embodiments, one or more slots may be a generalized drive modulecoupling circuit, for example where slots of the main board 24128 and/orthe intermediate coupling PCB 24502 are configured for receiving a drivemodule board.

An example inspection robot 24400, 24500 utilizes a first payloadcalibration set in response to the first payload interface circuitmounted in the housing, and to utilize a second payload calibration setin response to the second payload interface circuit mounted in thehousing. An example inspection robot 24400, 24500 utilizes a firstpayload instruction set in response to the first payload interfacecircuit mounted in the housing, and to utilize a second payloadinstruction set in response to the second payload interface circuitmounted in the housing. An example inspection robot 24400, 24500utilizes a first drive module calibration set in response to a firstdrive module interface circuit being positioned in the housing, anutilizes a second drive module calibration set in response to a seconddrive module interface circuit being positioned in the housing. Anexample inspection robot 24400, 24500 utilizes a first drive moduleinstruction set in response to a first drive module interface circuitbeing positioned in the housing, and utilizes a second drive moduleinstruction set in response to a second drive module interface circuitbeing positioned in the housing.

In certain embodiments, one or more boards 24112, 24116, 24402, 24114include indicator light(s), for example which may be visible through atransparent portion of the housing (e.g., a transparent top cover),whereby changing a board changes the available indicator lights. Incertain embodiments, one or more indicator lights may be positioned onthe housing, and electrically coupled to a board and/or the main board24128. The indicator lights allow the inspection robot to displayinformation visually available to an operator, for example a status ofthe inspection robot, an indication that inspection operations are beingperformed, and indication of the movement and/or direction of movementof the inspection robot, diagnostic information, or the like. In certainembodiments, indicator information may be provided to a base station,allowing the operator to confirm proper operations of the inspectionrobot using a computing device such as a laptop on the location. Theaddition of physical indicator lights on the inspection robot allows forthe operator to confirm operations while in visual range of theinspection robot, for example when away from the base station. Incertain embodiments, the first payload interface circuit includes afirst indicator light configuration (e.g., configured for the payloadassociated with the first payload interface circuit), and the secondpayload interface circuit includes a second indicator lightconfiguration (e.g., configured for the payload associated with thesecond payload interface circuit). In certain embodiments, the firstdrive module interface circuit includes a first indicator lightconfiguration (e.g., configured for the drive module associated with thefirst drive module interface circuit), and a second drive moduleinterface circuit includes a second indicator light configuration (e.g.,configured for the drive module associated with the second drive moduleinterface circuit). The inclusion of the indicator lights directly on agiven board allows for the customization of the lights for theparticular board, and reduces the complexity of electrically couplingthe lights and/or providing communications through an intermediatedevice such as the main board. The inclusion of the indicator lights onthe housing of the inspection robot allows for a consistent depictioninterface, allows for a more robust configuration of the lights (e.g.,more expensive and/or higher powered lights), and/or improves thevisibility of the indicator lights by being positioned at a selectedlocation on the outside of the housing.

An example inspection robot includes a payload board having a payloadinterface circuit and configured to operate the payload interface inresponse to a payload configuration value. Example and non-limitingpayload configuration values include one or more of a payloadcalibration set (e.g., sensor calibrations to be utilized with thepayload, for example UT cutoff times, sensor scaling values, sensoroperating ranges, sensor diagnostic ranges, payload downforce values tobe applied, etc.), an electrical interface description (e.g., A/Dprocessing, voltage ranges, current ranges, bitmap values, reservedelectrical diagnostic ranges, PWM parameters, etc.), and/or a payloadinstruction set (e.g., operating instructions, communication values ordescriptions, system responses to obstacles, detected features,diagnostic or other feature enable or disable instructions, etc.). Anexample inspection robot includes a board (e.g., the main board and/or atether board) having an inspection robot configuration circuit thatupdates the payload configuration value in response to communicationsreceived at the tether interface (e.g., instructions received from thebase station) and/or communications received at a wireless communicationinterface (e.g., instructions received via WiFi, Bluetooth, cellular, orother wireless communication procedure). For example, an operator at thelocation and/or a remote operator may provide updates to the payloadconfiguration value, which can be implemented without swapping a board,payload, or other device on the inspection robot.

An example inspection robot includes a drive board having a drive moduleinterface circuit configured to operate the drive module interface inresponse to a drive module configuration value. Example and non-limitingdrive module configuration values include one or more of: a drive modulecalibration set; an electrical interface description, and/or a drivemodule instruction set. An example inspection robot includes a board(e.g., the main board and/or a tether board) that updates the drivemodule configuration value in response to communications received at thetether interface and/or communications received at a wirelesscommunication interface. For example, an operator at the location and/ora remote operator may provide updates to the drive module configurationvalue, which can be implemented without swapping a board, drive module,or other device on the inspection robot.

Referencing FIG. 86, an example apparatus 24600 for performingconfirmation operations associated with inspection operations isdepicted schematically. The example apparatus 24600 includes acontroller 24602 having a number of circuits configured to functionallyexecute operations of the controller 24602. The example controller 24602includes an inspection description circuit 24604 that interprets andinspection definition value 24606, a payload status circuit 24206 thatprovides a payload identification value 24216 in response to a payloadspecific configuration 24212 and/or signals from a payload, aninspection integrity circuit 24612 that determines an inspectiondescription value 24614 in response to the inspection definition value24606 and the payload identification value 24216, and an inspectionreporting circuit 24620 that communicates the inspection descriptionvalue 24614 to an external device 24208. The controller 24602 may beincluded, in whole or part, on a board of the inspection robot, forexample on a main board, the tether board, a payload board, and/or adrive board. In certain embodiments, the controller 24602 may beincluded on a separate board, such as a fiduciary implementation board.In certain embodiments, the controller 24602, including any circuits,memory values, computer readable instructions related thereto, or thelike, may be updated via communications through the tether interfaceand/or wireless communication interface, and/or the controller 24602 maybe updated through a swap of a related board and/or the fiduciaryimplementation board.

An example inspection definition value 24606 includes one or more of: asensor type value (e.g., the sensor types and/or number of sensors to beused in the inspection operations, including potentially capabilityranges, accuracy, precision, etc.); a sensor identifier (e.g.,identifying specific sensors, sensor make and/or model, sensor hardwareand/or software versions, part numbers, etc. to be used in theinspection operations); a sensor calibration value (e.g., actualcalibration values, calibration ranges, calibration versions, etc. thatare to be used in inspection operations); a sensor processingdescription (e.g., specific processing operations, requirements,criteria, etc. to be utilized in the inspection operations); aninspection resolution value (e.g., spacing on the inspection surfacebetween interrogation points of the sensors or the like); and/or asensor diagnostic value (e.g., diagnostic operations, diagnostic types,sensors to be diagnosed, etc., that are to be used in the inspectionoperations). The inspection definition value 24606 allows for adefinition of inspection operations, configuration of the payload, areasof the inspection surface to be inspected and criteria for theinspection, and the like. The inspection definition value 24606 may beprovided by a responsible party for the inspection surface (e.g., anowner or operator of a facility including the inspection surface),according to an industry standard, according to a regulatoryrequirement, according to a risk assessment, or the like. In certainembodiments, the inspection definition value 24606 sets forth theinspection criteria to be performed for the inspection to be consideredto be properly executed.

An example controller 24602 includes a drive module status circuit 24608that provides a drive module status value 24616 (e.g., providingposition information for the inspection robot, inspection speeds, and/orconfirmation that the drive module(s) are operating properly and/orproviding reliable information), for example where the inspectiondefinition value 24606 includes one or more of an inspection surfacecoverage value (e.g., defining regions of the inspection surface thatare to be inspected, including inspection criteria for sub-regions ofthe inspection surface, positions of interest on the inspection surface,and/or confirming that inspection information is properly associatedwith position information on the inspection surface, etc.) and/or aninspection execution value (e.g., defining speed values of theinspection robot for regions of the inspection surface, for example toensure that sufficient inspection resolution, proper interrogation ofthe surface by sensors of the payload, etc. are performed) related tothe motive operation of the inspection robot. In a further example, theinspection integrity circuit 24612 further determines the inspectiondescription value 24614 in response to the drive module status value24616.

An example controller 24602 includes an encoder status circuit 24610that provides an inspection position value 24618 (e.g., providingposition information for the inspection robot, confirming inspectionspeeds and/or locations, and/or confirmation that the encoder isoperating properly and/or providing reliable information). In certainembodiments, the encoder status circuit 24610 may further provide anencoder status value (not shown), for example confirming that theencoder is operating properly, is in contact with the inspectionsurface, does not have faults or errors that degrade the positioninformation, or the like. In a further example, the inspection integritycircuit 24612 further determines the inspection description value 24614in response to the inspection position value 24618 and/or the encoderstatus value.

In certain embodiments, the inspection definition value 24606 includesone or more of: an inspection certification value (e.g., criteria thatare to be monitored and/or confirmed before, during, or after inspectionoperations; and/or an identifier for a certification to be completed,for example allowing the inspection description circuit 24604 toreference related information to determine a monitoring scheme to meetthe certification); an inspection data integrity value (e.g., listingdata to be monitored and/or confirmed, including related data providingevidence that primary inspection data is reliable, such as imaging data,active fault codes, diagnostic algorithm outputs, contact determinationsfor the encoder and/or payload, slip determinations for the inspectionrobot and/or wheels, or the like); a sensor diagnostic value (e.g., afault code, diagnostic result, and/or output of a diagnostic algorithmfor one or more sensors); a drive module diagnostic value; and/or anencoder diagnostic value. In certain embodiments, the inspectiondefinition value 24606 includes one or more of: a calibration versionvalue (e.g., versions of a calibration for a sensor, drive module,encoder, electronic board, or other component); a processing algorithmversion value (e.g., a version of a processing algorithm utilized by asensor, electronic board, or external device performing processingoperations for sensor data); a diagnostic version value; and/or acontrol algorithm version value (e.g., for a control algorithmassociated with the inspection operation, the inspection robot, a drivemodule, the encoder, a sensor, the payload, or other component). Incertain embodiments, the inspection definition value 24606 includes oneor more of: a sensing execution description (e.g., confirming thatsensors are operational and/or collecting data; confirming that theinspection robot positioning was properly made including positionsand/or speeds; and/or confirming that couplant delivery was properlyperformed); a motive operation execution description (e.g., confirmingthat motive operations were performed according to a schedule and/orsufficient to provide acceptable inspection operations, which mayinclude a position map with the inspection data, maximum speeds, stoplocations, or other supporting information); a data communicationexecution description (e.g., confirming that data communications wereavailable and sufficient during operations, confirming that any buffereddata was properly stored and recovered if data communications wereinterrupted, and/or confirming that communicated messages were properlyreceived); a diagnostic execution description (e.g., confirming thatrequired diagnostics were performed and active, and/or confirming thatdiagnostic algorithm results were acceptable); and/or a couplantdelivery execution description (e.g., confirming that couplant wasavailable and delivered acceptably to the sensors, and/or that couplantparameters such as temperature and composition were within acceptableparameters).

In certain embodiments, data responsive to the inspection definitionvalue 24606 may be included as data, for example the inspection data andany supporting data as indicated by operations of the controller 24602.In certain embodiments, data responsive to the inspection definitionvalue 24606 may be included as metadata with the inspection data, in aheader or other associated information with the inspection data, in aninspection report prepared and responsive to the confirmation operationsand/or certification of the inspection.

Without limitation to any other aspect of the present disclosure,example external devices 24208 for communication by the inspectionintegrity circuit 24612 include one or more of: a base station computingdevice; a facility computing device; a computing device communicativelycoupled to the inspection robot; a data acquisition circuit positionedwithin the housing of the inspection robot; a data acquisition circuitcommunicatively coupled to the inspection robot; and/or a cloud basedcomputing device communicatively coupled to the inspection robot.

Referencing FIG. 87, an example procedure 24700 for confirmingoperations associated with inspection operations is schematicallydepicted. The example procedure 24700 includes an operation 24702 tointerpret an inspection definition value, and an operation 24704 toprovide a payload identification value in response to at least one of apayload specific configuration or signals from a payload. An exampleoperation 24704 includes determining an identity of the payload and/orsensors of the payload, for example using a specific identifier, partnumbers, header information from messages from the payload, or the like.In certain embodiments, operation 24704 includes identifying the payloadand/or sensor information (e.g., sensor precision, information typeprovided, etc.) from signals provided by the payload (e.g., using aheuristic, expert system, and/or comparing sensor messages to expectedmessaging formats, estimated values, etc.). The example procedure 24700includes an operation 24706 to determine an inspection description value(e.g., values confirming that the inspection definition value has beenmet, and/or areas where inspection operations did not meet theinspection definition value) in response to the inspection definitionvalue and the payload identification value, and an operation 24708 tocommunicate the inspection description value to an external device.

Referencing FIG. 88, an example procedure 24800 for confirmingoperations associated with inspection operations is schematicallydepicted. The example procedure 24800 is similar to procedure 24700, butincludes further operations, any one or more of which may be present incertain embodiments. The example procedure 24800 includes an operation24802 to determine a drive module status value in response to aninspection surface coverage value and/or an inspection execution value,and the operation 24706 further determining the inspection descriptionvalue in response to the drive module status value. The exampleprocedure 24800 includes an operation 24804 to determine an encoderstatus value and/or an inspection position value in response to aninspection surface coverage value and/or an inspection execution value,and the operation 24706 further determining the inspection descriptionvalue in response to the encoder status value and/or the inspectionposition value.

Referencing FIG. 89, an example procedure 24900 for confirmingoperations associated with inspection operations is schematicallydepicted. The example procedure 24900 is similar to procedure 24700, butincludes further operations, any one or more of which may be present incertain embodiments. The example procedure 24900 includes an operation24902 to interpret a data collection configuration in response to theinspection definition value, an operation 24904 to collect responsivedata for the data collection configuration during an inspectionoperation, and operation 24706 further includes determining theinspection description value in response to the responsive data for thedata collection configuration. Example operations 24904 include one ormore operations such as: collecting a component identification valuecollecting a component type value, collecting a component status value,collecting a component calibration version value, collecting adiagnostic version value, collecting a component processing algorithmvalue, and/or collecting a component control algorithm version value.

An example inspection definition value 24606 may include one or more of:a sensor calibration value, a sensor identifier, a sensor type value, adrive module identifier (e.g., identifying specific drive module, drivemodule make and/or model, drive module hardware and/or softwareversions, part numbers, etc. to be used in the inspection operations); adrive module calibration value (e.g., actual calibration values,calibration ranges, calibration versions, etc. that are to be used ininspection operations); a drive module type value (e.g., the drivemodule type to be used in the inspection operations, includingpotentially capability ranges, accuracy, precision, etc.); a controlboard identifier (e.g., identifying specific control board, controlboard make and/or model, control board hardware and/or softwareversions, part numbers, etc. to be used in the inspection operations),or a control board type value (e.g., the control board type to be usedin the inspection operations, including potentially capability ranges,etc.).

An example inspection definition value 24606 may include one or more ofa sensor usage value (e.g. a usage time period, collected data by theinspection robot during usage, an event occurring during usage, etc.), acontrol board usage value; (e.g. a usage time period, collected data bythe inspection robot during usage, an event occurring during usage,etc.); or a drive module usage value (e.g. a usage time period,collected data by the inspection robot during usage, an event occurringduring usage, etc.).

In certain embodiments, inspection robot 24100 and external device 24208are configured to verify a component of the inspection robot 24100 iscorrectly included in the inspection robot, is properly calibrated, andincludes the capabilities to perform inspection operations on aninspection surface.

In certain embodiments, inspection robot 24100 receives anidentification verification value (e.g., component correctly included)in response to communicating the inspection description value toexternal device 24208. In certain embodiments, inspection robot 24100receives a calibration verification value (e.g., proper calibration fora component) in response to communicating the inspection descriptionvalue to the external device. In certain embodiments, inspection robot24100 receives a type of value verification value (proper capabilitiesfor a component) in response to communicating the inspection descriptionvalue to the external device.

An example inspection definition value 24606 may include one or more of:a sensor calibration value, a sensor identifier, a sensor type value, adrive module identifier (e.g., identifying specific drive module, drivemodule make and/or model, drive module hardware and/or softwareversions, part numbers, etc. to be used in the inspection operations); adrive module calibration value (e.g., actual calibration values,calibration ranges, calibration versions, etc. that are to be used ininspection operations); a drive module type value (e.g., the drivemodule type to be used in the inspection operations, includingpotentially capability ranges, accuracy, precision, etc.); a controlboard identifier (e.g., identifying specific control board, controlboard make and/or model, control board hardware and/or softwareversions, part numbers, etc. to be used in the inspection operations),or a control board type value (e.g., the control board type to be usedin the inspection operations, including potentially capability ranges,etc.).

An example inspection definition value 24606 may include one or more ofa sensor usage value (e.g. a usage time period, collected data by theinspection robot during usage, an event occurring during usage, etc.), acontrol board usage value; (e.g. a usage time period, collected data bythe inspection robot during usage, an event occurring during usage,etc.); or a drive module usage value (e.g. a usage time period,collected data by the inspection robot during usage, an event occurringduring usage, etc.).

In certain embodiments, inspection robot 24100 and external device 24208are configured to verify a component of the inspection robot 24100 iscorrectly included in the inspection robot, is properly calibrated, andincludes the capabilities to perform inspection operations on aninspection surface.

In certain embodiments, inspection robot 24100 receives anidentification verification value (e.g., component correctly included)in response to communicating the inspection description value toexternal device 24208. In certain embodiments, inspection robot 24100receives a calibration verification value (e.g., proper calibration fora component) in response to communicating the inspection descriptionvalue to the external device. In certain embodiments, inspection robot24100 receives a type value verification value (proper capabilities fora component) in response to communicating the inspection descriptionvalue to the external device.

External device 24208 may determine at least one of an identificationverification value, calibration verification value, or type valueverification value in response to communicating the inspectiondescription value to the external device. External device 24208 may alsonotify a user in response to determining the at least one of theidentification verification value, calibration verification value, ortype value verification value. The user may be notified by transmittinga notification to a user device or tagging the data stored by externaldevice associated with a component with the determined value.

In certain embodiments, external device 24208 may update or modify acomponent data log including a component historical usage value inresponse to receiving the inspection description value. The updating ormodifying may include storing the at least one of the sensor usagevalue, the control board usage value, or the drive module usage value.In certain embodiments, external device 24208 may use the componenthistorical usage value to predict a failure of the component ofinspection robot 24100. In certain embodiments, external device 24208receives inspection description values from a fleet of inspection robotsincluding inspection robot 24100, and uses the inspection descriptionvalues to determine at least one of: a command for inspection robot24100, a component fault of inspection robot 24100, an incorrectcalibration of one of the components of inspection robot 24100, or anestimated remaining life for a component of inspection robot 24100, toname but a few examples.

Referencing FIG. 91, an example inspection robot 25000 is schematicallydepicted. The example inspection robot 25000 includes a housing 24118,where the housing 24118 includes at least a portion of a couplantretaining chamber 25002. In the example of FIG. 90, the couplantretaining chamber 25002 is formed between a bottom surface of thehousing 24118 and an inspection surface. For example, referencing FIG.92, an example bottom view of an inspection robot 25000 is depicted,with a portion of the couplant retaining chamber 25002 formed by thehousing 24118 depicted. The couplant retaining chamber 25002, wherepresent, provides for a mechanism for providing thermal coupling betweenthe couplant flowing through the inspection robot 25000 and componentsof the inspection robot 25000, for example to provide cooling and/orheat management for the relevant components. In certain embodiments, thecouplant retaining chamber 25002 may additionally or alternatively beprovided within the housing 24118, including with the couplant retainingchamber 25002 formed at least in part utilizing the housing 24118 (e.g.,an interior surface of the housing 24118), and/or formed completelywithin the housing 24118, for example as a dedicated fluid retainingchamber.

The example inspection robot 25000 further includes an electronic board25004 that is at least selectively thermally coupled to the couplantretaining chamber 25002. The electronic board 25004 may be any board,PCB, controller, portions thereof, and/or combinations thereof (in wholeor part) as set forth throughout the present disclosure. Withoutlimitation to any other aspect of the present disclosure, an exampleelectronic board 25004 includes one or more of: a main board, a payloadboard, a drive board, a tether board, a data acquisition circuit, amodular board, and/or a stackable board. In certain embodiments, thethermal coupling includes thermal coupling to a shared wall or separator(e.g., a wall of the housing 24118), thermal coupling to a conductivepath to the retaining chamber (e.g., a heat pipe, conductive materialforming a thermal path, or the like), and/or variable thermal couplingimplemented with a variable heat transfer rate (e.g., modulating acontact exposure area between the electronic board 25004 and thecouplant retaining chamber 25002, changing a flow rate of couplant inthe couplant retaining chamber 25002, or the like).

The example inspection robot 25000 includes a couplant input port, forexample present as a portion of the tether interface 24405, where thecouplant input port is fluidly coupled to a couplant source on a firstside (e.g., via the tether 24110 in the example of FIG. 91), and fluidlycoupled to a couplant flow path 25010 on a second side. The exampleinspection robot 25000 further includes a drive module (e.g., depictedas a wheel 25008 and drive motor 25006, in the example of FIG. 91). Theexample drive module includes a drive motor 25006 operatively coupled toat least one wheel 25008, and may be embodied in whole or part accordingto any drive module set forth throughout the present disclosure. Theexample drive module includes the wheel(s) 25008 positioned such thatthe wheel(s) 250008 engage the inspection surface when the inspectionrobot 25000 is positioned on the inspection surface, thereby allowingthe drive module to move the inspection robot 25000 along the inspectionsurface. The example inspection robot 25000 includes two drive modules,one positioned on each side, allowing for the inspection robot 25000 tobe steered (e.g., using steerable wheels, opposing motion of the wheelson each drive module, and/or combined motion such as a slowed or stoppedwheel on one side and a faster moving wheel on the other side).

The example inspection robot 25000 further includes a payload 24102including at least one sensor mounted thereon, where the payload 24102is coupled to the housing 24118 such that the sensor(s) selectivelyengage the inspection surface when the inspection robot is positioned onthe inspection surface. In the example, selective engagement of thesensors with the inspection surface includes the capability of thepayload 24102 to lift the sensor(s) off the surface, the capability toturn the sensor(s) on or off, or any other selective engagement as setforth throughout the present disclosure. In certain embodiments, thesensors are configured to be engaged with the inspection surface inresponse to the inspection robot 24100 being positioned on theinspection surface. The payload(s) 24102 may be coupled directly to thehousing 24118 (e.g., engaging a mount or rail of the housing 24118)and/or to a mount of one or more drive module(s) that are coupled to thehousing.

The example inspection robot 25000 further includes a couplant flow path25010 that fluidly couples the couplant input port portion of the tetherinterface 24405 to the couplant retaining chamber 25002. In the exampleof FIG. 91, the couplant flow path 25010 is depicted schematically forclarity of illustration of the relationship of components of theinspection robot 25000 with the couplant flow path 25010. The couplantflow path 25010 may be embodied in any form using hardware compatiblewith the couplant fluid, for example using tubes, hoses, fluid pathsformed in a housing of a component, connectors, or the like. In certainembodiments, the couplant flow path 25010 may include valves (includingbut not limited to certain valve configurations depicted in the presentdisclosure) and/or pumps (including but not limited to certain pumpconfigurations depicted in the present disclosure). In the example ofFIG. 90, a single couplant flow path 25010 is depicted, flowing throughthe housing 24118, the drive module, the payload 24102, a sensor (e.g.,provided to a delay line provided to give a consistent acousticenvironment for a sensor acoustically coupled to the inspection surfaceduring operations of the inspection robot 25000), and finally to thecouplant retaining chamber 25002. In the example of FIG. 91, thecouplant flow path 25010 includes couplant that is emitted from thesensors (and/or sled, delay line, etc.) during operations, which flowsover the inspection surface and into the couplant retaining chamber25002. In certain embodiments, a second couplant flow path (not shown)is provided, for example flowing through the drive module, payload,and/or sensor(s) on the other side of the inspection robot 25000.Referencing FIG. 93, an example inspection robot 25000 is depictedschematically in a side view. In certain embodiments, the embodiment ofFIG. 93 is consistent with the embodiment of FIG. 91, with componentsremoved and simplified to illustrate aspects of the present disclosure.In the example of FIG. 93, the couplant retaining chamber 25002 isformed between a shaped bottom surface of the housing 24118 and theinspection surface 25202. In the example of FIG. 93, the sensor isembodied as a sensing element 25206 (e.g., an inducer of a UT sensor), adelay line chamber 25208, and a sensor housing 25204. In certainembodiments, the sensor housing 25204 and/or delay line chamber 25208may be formed by, and/or included as a part of, the payload 24102 and/ora sled mounted on the payload. In the example of FIG. 93, the couplantflow path 25010 includes a portion flowing from the sensor to thecouplant retaining chamber 25002.

The example couplant retaining chamber 25002 formed between the housing24118 and the inspection surface depicts the couplant flowing into thecouplant retaining chamber 25002 from the sensors. In certainembodiments, the couplant retaining chamber 25002 may additionally oralternatively be charged with couplant through a direct path from thehousing 24118, for example utilizing a hole in the housing to thecouplant retaining chamber, which may be controlled, for exampleutilizing a valve, diaphragm, iris, or the like. In certain embodiments,control elements, boards, circuits, or the like that are configured tocontrol the couplant flow path 25010 configuration may be configured tocontrol couplant flow through the hole (where present) to the couplantretaining chamber 25002. An example couplant flow path fluidly couples,in order, the couplant input port, the drive module, the payload, andthen the couplant retaining chamber.

Referencing FIG. 94, an example drive module is schematically depicted,the drive module formed from a wheel 25008 and a drive motor 25006. Theexample of FIG. 94 includes a heat exchanger 25302 positioned on thedrive module, where the heat exchanger 25302 thermally couples thecouplant flow path 25010 to the drive motor 25006. The example heatexchanger 25302 is depicted schematically, but may be embodied as a heattransfer device of any type, for example a shell-and-tube heatexchanger, a conductive contact surface facilitating heat transferbetween the couplant flow path 25010 and the drive motor 25006, and/or acoolant jacket of the drive motor 25006. The example of FIG. 94 includesa routing valve 25304 configured to control thermal coupling of thecouplant flow path 25010 and the drive motor 25006, for examplecontrolling flow through the heat exchanger 25302 relative to flowaround the heat exchanger 25302, where in the example flow around theheat exchanger 25302 does not have significant thermal coupling with thedrive motor 25006, and/or does not flow through the drive motor 25006 atall (not shown). In the example of FIG. 94, the routing valve 25304 maybe a three-way valve (e.g., allowing for flow in both paths, includingat controlled flow rates), a switching valve (e.g., allowing for flow ineither path), or any other flow control arrangement, whether utilizing avalve or otherwise.

Referencing FIG. 95, an example inspection robot is schematicallydepicted illustrating an internal couplant retaining chamber and certaincontrol features for the couplant flow path 25010. In the example ofFIG. 95, certain components are not depicted for clarity of the presentdescription. The example of FIG. 95 includes a couplant retainingchamber 25410 positioned within the housing 24118. The example of FIG.95 includes a routing valve 25412 configured to selectively bypass thecouplant flow path 25010 past the couplant retaining chamber 25410. Forexample, the routing valve 25412 in a first position provides for thecouplant to flow directly through the housing 24118, where the routingvalve 25412 in a second position provides for the couplant to flowthrough the couplant retaining chamber 25410. In certain embodiments,the routing valve 25412 can adjust the couplant flow between both paths,with a portion of the couplant flowing directly through the housing24118 and the remaining couplant flowing through the couplant retainingchamber 25410. The routing valve 25412 allows for balancing coolingoperations and/or couplant first exposure (e.g., where the couplanttemperature is relatively lower before thermal contact with components)to selected components, such as between a board (e.g., the main board, adiagnostic execution circuit, etc.) and a drive motor. The example ofFIG. 96 includes a heat pipe 25414 that thermally couples the board(s)to the couplant retaining chamber 25410. In the example of FIG. 96, theboards include a main board 25402, and several additional boards 25404,25406, 25408. In the example, the additional boards 25404, 25406, 25408may be modular boards (e.g., interchangeable between slots of at leastsome other boards), dedicated boards (e.g., a payload board, driveboard, data acquisition circuit, and/or tether board), and/or stackableboards (e.g., boards having a shared spacing in a given frame ofreference, such as vertically stacked, horizontally stacked, or thelike). In the example of FIG. 94, the main board 25402 is depicted belowthe heat pipe 25414, and the additional boards 25404, 25406, 25408 aredepicted above the heat pipe 25414, for example to provide thermalcontact between each board and the heat pipe 25414. Any arrangement maybe utilized, and may be selected based on the expected heat to begenerated in given boards, the temperature limits of given boards, orthe like. In certain embodiments, the heat pipe 25414 may be thermallycoupled to any heat generating component of the inspection robot, forexample a main board, payload board, drive board, modular electronicboard, a power converter (e.g., configuring power received through thetether for provision to components of the inspection robot), and/or adata acquisition circuit. A data acquisition circuit may be formed as apart of another board (e.g., a payload board), a dedicated dataacquisition circuit (e.g., configured to gather data and communicate thedata to an external device), and/or a circuit configured to manageselected data elements, such as imaging data, video data, or the like.In certain embodiments, the data acquisition circuit generatessignificant heat, such as during high data rate operations.

An example inspection robot includes a couplant flow path that fluidlycouples, in order, the couplant input port, the payload (and/or asensor), and the couplant retaining chamber. In certain embodiments,such as depicted in FIG. 96, the couplant flow path includes a bypasscouplant path fluidly coupling the couplant input port to the couplantretaining chamber, and/or a routing valve 25412 configured to modulate acouplant flow through the bypass couplant path.

Referencing FIG. 96, an example inspection robot is schematicallydepicted, configured in a similar arrangement to the example of FIG. 95.The example inspection robot includes a housing recirculation path25504, depicted in the example as controllable by a routing valve 25502that controls flow exiting the couplant retaining chamber 25410 betweenthe main couplant flow path 25010 leaving the housing 24118 (in theexample) and the housing recirculation path 25504. In certainembodiments, control of the routing valve 25502 can be utilized toincrease the flow rate of couplant through the couplant retainingchamber 25410, thereby increasing a heat transfer rate (at least duringtransient operation, until the couplant temperature rises sufficientlyto reduce the effective heat transfer rate) between the couplantretaining chamber 25410 and the heat pipe 25414 and/or other cooledcomponents. In the example of FIG. 55, the bypass flow path for thecouplant retaining chamber 25410 is omitted, but may be present inaddition to the housing recirculation path 25504 for certainembodiments. The example of FIG. 96 further includes a recirculationpump 25506, for example to enhance a recirculating fluid flow rate. Incertain embodiment, other flow control elements such as a check valve(e.g., to protect the tether and/or couplant source from pressuregenerated by the recirculation pump 25506) may be provided.

The example couplant flow arrangements and/or flow control elements ofthe embodiments depicted in FIGS. 91-96 may be utilized, in whole orpart, with any inspection robots, systems, assemblies, or otherembodiments as set forth throughout the present disclosure. In certainembodiments, valves, pumps, bypass flow paths, recirculating flow paths,or the like, may be controlled by any controller, circuit, board, orsimilar component as set forth herein, and/or may be utilized duringoperations of any procedures, methods, algorithms, or other operationaldescriptions as set forth herein.

Referencing FIG. 97, an example inspection robot is schematicallydepicted, illustrating example heat generating components that may bepresent in certain embodiments. In the example of FIG. 97, the couplantflow path(s) and/or couplant retaining chamber(s) are omitted forclarity of the illustration. In the example of FIG. 97, a main board25402, modular boards 25404, 25406, 25408, a data acquisition circuit25610 (e.g., dedicated to an imaging and/or video sensor, and/or furtherconfigured to collect and communicate payload data), and a powerconverter 25612. Any one or more of the components may be thermallycoupled to a couplant flow path, including any selected order of contactwith the couplant flow path, and/or including providing thermal contactwith a heat pipe and/or conductive path, and/or a couplant retainingchamber.

Referencing FIG. 98, an example procedure 25700 for cooling one or morecomponents of an inspection robot is schematically depicted. The exampleprocedure 25700 includes an operation 25702 to operate an inspectionrobot to interrogate an inspection surface with at least one sensormounted on the inspection robot, an operation 25704 to supply a couplantto a couplant input port of the inspection robot, and an operation 25706to thermally contact the couplant with an electronic board of theinspection robot. Referencing FIG. 99, an example procedure 25800 isdepicted, which may be utilized in conjunction with and/or as a part ofprocedure 25700. The example procedure 25800 includes an operation 25802to thermally contact the couplant with a drive module of the inspectionrobot before the thermally contacting the couplant with the electronicboard (e.g., by passing the couplant to the drive module, and then backinto the housing; and/or by passing the couplant to the drive module,then to an external couplant retaining chamber, such as through thepayload). The example procedure 25800 further includes an operation25804 to provide the couplant to a delay line chamber of a sensor(s)before thermally contacting the couplant with the electronic board. Incertain embodiments, an operation to thermally contact the couplant withthe electronic board includes thermally contacting the couplant with aheat pipe thermally coupled to the electronic board. In certainembodiments, thermally contacting the couplant with the heat pipefurther includes contacting the couplant with at least one additionalheat generating component of the inspection robot (e.g., providingthermal contact to the electronic board and at least one additional heatgenerating component). In certain embodiments, a procedure includes, inorder, thermally contacting the couplant with a drive motor, providingthe couplant to a delay line chamber associated with the sensor(s), andthen performing the thermal contact of the couplant with the electronicboard. An example procedure includes an operation (not shown) torecirculate at least a portion of the couplant within a housing of theinspection robot.

Referencing FIG. 100, an example apparatus 25900 is depicted forperforming thermal management of an inspection robot and/or componentsof an inspection robot. The example apparatus may be utilized, in wholeor part, with any inspection robot, system, assembly, or otherembodiment set forth herein. The example apparatus 25900 may beembodied, in whole or part, on any board, controller, circuit, or thelike as set forth herein. In certain embodiments, the example apparatusmay be utilized, in whole or part, to perform all or a portion of anyprocedure, method, and/or operation described herein. The exampleapparatus 25900 include a controller 25902 which may include atemperature determination circuit 25904 structured to interpret aninspection temperature value 25910, and a temperature management circuit25906 structured to determine a temperature management command 25912 inresponse to the inspection temperature value 25910. The exampleapparatus 25900 further includes a temperature response circuit 25098that provides the temperature management command 25912 to a temperaturemanagement device 25914 associated with an inspection robot.

Example and non-limiting inspection temperature value(s) 25910 includeone or more of: a temperature of a component of the inspection robot(e.g., a board, circuit, drive motor, etc.); an ambient temperaturevalue; a temperature of a couplant provided to the inspection robot(e.g., a temperature of the couplant at the couplant inlet port, and/orat any position throughout the couplant flow path); and/or a temperatureof an inspection surface. In certain embodiments, the inspectiontemperature value 25910 allows for the determination that a component isover a temperature limit, approaching a temperature limit, gaining netheat (e.g., having a rising temperature), losing net heat (e.g., havinga falling temperature), the effectiveness of thermal exchange betweenthe couplant and the component, or the like.

An example temperature management command 25912 includes a recirculationvalve command, and where the temperature management device 25914includes a recirculation valve configured to modulate a recirculationrate of couplant within a housing of the inspection robot (e.g.,recirculating through an internal couplant retaining chamber), where therecirculation valve is responsive to the recirculation valve command. Anexample temperature management command 25912 includes a data acquisitionadjustment value, where the temperature management device includes adata acquisition circuit responsive to the data acquisition adjustmentvalue to adjust a rate of data collection from a payload of theinspection robot. For example, a data collection rate of the dataacquisition circuit may be reduced to protect the data acquisitioncircuit, to reduce temperature generated by the data acquisitioncircuit, or the like. An example temperature management command 25912includes a routing valve command, where the temperature managementdevice includes a routing valve configured to adjust a couplant flowrouting through the inspection robot, for example in response to therouting valve command. An example routing valve command includes a firstcouplant flow regime or a second couplant flow regime, where theposition of the routing valve command selects a flow regime and/ormodulates between the two flow regimes. An example first couplant flowregime includes, in order, providing the couplant in thermal contactwith a drive motor and then with an electronic board positioned within ahousing of the inspection robot. An example second couplant flow regimeincludes providing the couplant in thermal contact with an electronicboard positioned within the housing of the inspection robot. Anotherexample second flow regime includes, in order, providing the couplant inthermal contact with the electronic board, then in thermal contact withthe drive motor, and then in a second thermal contact with theelectronic board.

An example temperature management command 25912 includes a couplant flowrate command, where the temperature management device includes arecirculation valve and/or a recirculation pump, thereby controlling therecirculation flow rate responsive to the couplant flow rate command. Anexample temperature management device includes a pump and/or a valveassociated with a couplant source (e.g., associated with a base station,a couplant reservoir, etc.) that provides couplant to the inspectionrobot, where the pump and/or valve is responsive to the couplant flowrate command.

An example temperature management command 25912 includes a couplanttemperature command, where the temperature management device includes acouplant source configured to provide couplant to the inspection robot,and where the couplant source is responsive to the couplant temperaturecommand. For example, couplant source may have refrigeration or othercooling capabilities for the couplant fluid, and/or the couplant sourcemay include more than one fluid source or reservoir at distincttemperatures, utilizing a selected ratio, and/or switching between fluidsources, responsive to the couplant temperature command. For example, awarmer source (or uncooled source) may be utilized during an earlyinspection phase, inspection operations having a lower ambienttemperature and/or inspection surface temperature (e.g., where thetemperature may increase throughout the inspection, such as when theinspection robot climbs a pipe, proceeds more deeply into a piece ofequipment, etc.), utilizing a cooler source (or actively cooled source)during a later inspection phase, and/or inspection operations having ahigher ambient temperature and/or inspection surface temperature.

An example temperature management command 25912 includes an inspectionposition command, where the temperature management device includes adrive module responsive to the inspection position command In certainembodiments, the inspection position command may be utilized to move theinspection robot more quickly over high temperature regions, to slowdown during high temperature operations (e.g., to reduce powerconsumption and/or heat generation during higher temperatureoperations), and/or to modulate the speed and/or position of theinspection robot to keep one or more components within temperaturelimits. In certain embodiments, the inspection position command may beutilized to inspect high temperature regions in parts, for examplemoving the inspection robot into and out of a high temperature areauntil inspection operations are completed.

An example temperature management command 25912 includes an operationallimit command, where the temperature management device includes at leastone heat generating component of the inspection robot, where the heatingcomponent(s) are responsive to the operational limit command. Theoperational limit command may be utilized to limit heat generation(e.g., reducing power consumption or other heat generating operations ofthe component), and/or limiting operations to protect the component dueto the temperature (e.g., reducing a power throughput, operating speed,or the like for a component due to temperature vulnerability). Theexample heat generating component includes any heat generating componentset forth herein, any component utilizing power herein, and/or any oneor more of a main board, a payload board, a drive module board, amodular electronic board, a power converter, and/or a data acquisitioncircuit.

Referencing FIG. 101, an example procedure 26000 for performing thermalmanagement of an inspection robot and/or components of an inspectionrobot is schematically depicted. The example procedure 26000 includes anoperation 26002 to interpret an inspection temperature value, anoperation 26004 to determine a temperature management command inresponse to the inspection temperature value, and an operation 26006 tooperate a temperature management device associated with an inspectionrobot in response to the temperature management command.

Referencing FIG. 102, an example controller 26102 for flexibleconfiguration and/or operation of a drive module is schematicallydepicted. The example controller 26102 may be included with any system,apparatus, controller, circuit, and/or board as set forth herein. Anexample controller 26102 is provided on a drive board (and/or drivemodule board). The example controller 26102 includes a drive moduleconfiguration circuit 26104 that determines a drive module couplingconfiguration 26108, for example including one or more of a drive moduleidentification value, a drive module coupling position value (e.g.,which interface plate, electronic board, and/or which side of thehousing where the drive module is coupled), and/or a drive moduleelectrical description. The example controller 26102 further includes adrive execution circuit 26106 that determines drive module commands26110 in response to the drive module coupling configuration 26108(e.g., providing instructions, protocols, and/or electricalcharacteristics to control the drive module) and an inspection positioncommand 26116 (e.g., a requested and/or commanded position and/orvelocity of the inspection robot, a temperature management determinedposition command, or the like). The example controller 26102 includes adrive module interface circuit 26107 that provides drive commands 26112to the first drive module and/or second drive module (where present) inresponse to the drive module commands 26110. The operations of thecontroller 26102 allows for dynamic replacement and/or swapping of drivemodules 26114, for example to change between drive modules havingvarying capability, to replace a failed and/or faulted drive module,and/or to manage utilization of drive modules. In certain embodiments,operations of the controller 26102 allow for swapping drive modulesbetween sides (e.g., reversing a movement logic for a drive modulemoving from a right side to a left side, etc.), and/or to respond tovarying gear ratios between drive modules. In certain embodiments, aswapped drive module includes a same component description (e.g., samepart number, interface description, command values, electricalcharacteristics, etc.). In certain embodiments, drive modules may behanded (e.g., one set of drive modules configured to mount on a leftside of the inspection robot, and another set of drive modulesconfigured to mount on a right side of the inspection robot). In certainembodiments, drive modules may have mounting positions on a same side(e.g., a forward position, a rearward position, both positions, and/or aposition that is forward for the drive module mounted on a first sideand rearward for the drive module mounted on a second side).

Referencing FIG. 103, an example procedure 26200 for configuring aninspection robot and/or swapping drive modules of an inspection robot isschematically depicted. The example procedure 26200 includes anoperation 26202 to couple a payload to a first removeable interfaceplate of an inspection robot, an operation 26204 to couple a drivemodule to a second removeable interface plate, and an operation 26206 tooperate the inspection robot to interrogate at least a portion of aninspection surface with the payload. Referencing FIG. 104, an exampleprocedure 26300 further includes an operation 26302 to adjust anelectronic board coupled to the first removeable interface plate, and anoperation 26304 to adjust an electronic board coupled to the secondremoveable interface plate. Example operations 26302, 26304 to adjusteach board include operations such as: configuring an electricalinterface of the electronic board, configuring a calibration positionedon an interface circuit of the electronic board, or configuring acontrol algorithm embodied as instructions stored on a computer readablemedium and positioned on the board.

Referencing FIG. 105, an example procedure 26400 to swap a drive moduleand/or a payload of an inspection robot is schematically depicted. Theexample procedure 26400 may be performed, in whole or part, incombination with procedure 26200, 26300, and/or portions thereof. Theexample procedure 26400 includes an operation 26402 to swap the drivemodule with a second drive module, and/or an operation 26404 to swap thepayload with a second payload. In certain embodiments, operations 26402and/or 26404 includes swapping a removeable interface plate, and/or anelectronic board, with the swap of the drive module and/or the payload.Referencing FIG. 106, an example procedure 26500 to configure aninspection robot utilizing a second payload are schematically depicted.The example procedure 26500 includes an operation 26502 to determine apayload identification value of the second payload, and an operation26504 to adjust a configuration in response to the payloadidentification value. Example and non-limiting operations 26504 includeone or more of: requesting a sensor calibration value update, requestinga sensor processing description update, a requesting a payload controlalgorithm update, requesting a sensor diagnostic value update, adjustinga sensor calibration value, adjusting a sensor processing description,adjusting a payload control algorithm, and/or adjusting a sensordiagnostic value. Referencing FIG. 107, the example procedure 26700includes an operation 26702 to provide an incompatibilitynotification—for example indicating that a calibration, sensorprocessing description, payload control algorithm, and/or sensordiagnostic value, is not compatible with a physically coupled payload,sensor, and/or drive module. An example operation 26702 includes anoperation to provide an indicator light warning configuration. Anexample operation 26702 includes an operation to provide anincompatibility communication to an external device.

Referring to FIG. 108, an inspection robot 26800, may include a housing26802, a drive module 26804, a payload 26808, and a payload engagementdevice 26810. The drive module 26804 may include at least one wheel26812, and a motor 26814. The drive module 26804 is operationallycoupled to the housing 26802. The payload engagement device 26810operationally couples the payload 26808 to the drive module 26804. Thepayload 26808 may include at least one sensor 26818 mounted to thepayload 26808. In embodiments there may be multiple drive modules ordrive modules with multiple wheels and motors.

The payload engagement device 26810 may be active or passive and mayinclude a gas spring, an actuator, an electrically controlled spring, orthe like. The payload engagement device 26810 may be adjustable withrespect to loading on a spring (passive or active), angle at which thepayload engagement device 26810 engages with the payload 26808, wherethe payload engagement device 26810 is coupled to the drive module,between defined positions such as a position in which the sensor engagesan inspection surface, a position in which the payload is lifted awayfrom the surface, a resting position, and the like.

Referring to FIG. 109, an inspection robot 200, may include a housing26802, at least one drive module 26804, a payload 26808, and a payloadengagement device 26810. The drive module 26804 may include at least onewheel 26812, and a motor 26814. The drive module 26804 is operationallycoupled to the housing 26802. The inspection robot 26900 may furtherinclude a sled 26902 including a sensor 26904, a controller 26906. Thesled 26902 is operationally coupled to the payload 26808. The payloadengagement device 26810 operationally couples the payload 26808 to thedrive module 26804 and is structured to regulate an engagement of thesled 26902 with an inspection surface.

The inspection robot may further include a controller 26906. Thecontroller is shown in the housing 26802, but this representation isonly for illustrative purposes and is not meant to limit the location ofthe controller 26906. The controller 26906 may include a payloadengagement determination circuit 26908, structured to determine a sledengagement parameter 26910 in response to an engagement value 26912which is representative an interactive force between the sled 26902 andthe inspection surface. The engagement value 26912 may be determined bythe sled 26902 or the payload engagement device 26810 and then providedto the payload engagement determination circuit 26908. The controller26906 may further include a payload engagement circuit 26916 todetermine a payload engagement change parameter 26914 (whether thereneeds to be a change in engagement between the sled and the inspectionsurface and it so what kind of change) based, at least partially, on thesled engagement parameter 26910. A payload engagement control circuit26918 may provide a payload action command 26920, in response, at leastpart on the payload engagement change parameter 26914. Payload actioncommands 26920 may include adjust payload height, raise payload, lowerpayload, set payload height, adjust payload angle, adjust angle of forceapplied to payload, move to defined position (e.g. a first positionwhere the sensor engages the inspection surface, a second position wherethe payload is lifted away from the inspection surface, a third positionfor when the robot is not in use, and the like), adjust a payloadpressure, set a spring compression, and the like.

Referring to FIG. 110, an inspection robot 27000, may include a housing26802, a drive module 26804 (at least one and possibly multiple), acontroller 27004, and an encoder 27002 positioned within the footprintof the housing. The footprint of the housing (or housing footprint)refers to the space between the housing 26802 and the inspection surfacewhen viewed from above the housing 26802. Positioning the encoder 27002closer to a horizontal center of the housing footprint may result moreaccurate determinations of the robot's position. In an illustrativeexample, an encoder positioned in a center of a housing footprint and anencoder position on a drive module beyond the housing footprint wouldprovide different distances travelled when the robot turned with theencoder positioned on the drive module travelling significantly further.

The drive module 26804 includes a wheel 26812 and a motor 26814. Thedrive module is operatively coupled to the housing 26802 and enablesmovement of the inspection robot 27000 along an inspection surface. Theencoder 27002 may include an encoder wheel 22202, and an encoderconnector 22210 to couple the encoder 27002 to the housing 26802. Thecontroller 27004 may include an encoder conversion circuit 27012 tocalculate a distance value 27014 representative of how far the robot hastraveled in an interval based on a movement value 27016 received fromthe encoder 27002. The controller 27004 may further include a locationcircuit 27020 to determine a robot location value 27022 or a robot speedvalue 27024 based on the distance value 27014. A position commandcircuit 27028 may provide a position action command 27030 in response,at least in part, to the robot location value 27022 or the robot speedvalue 27024. The drive module 26804 may be responsive to the positionaction command 27030.

Position action commands 27030 may include: a command to integrate therobot location value 27022 with any data obtained at that location, acommand to communicate the robot location value 27022 or the robot speedvalue 27024 to a remote location 27032, a halt command, a set speedcommand, a change speed command, a change direction command, a returnhome command, and the like.

The encoder 27002 may be positioned in a center of the housingfootprint. The encoder 27002 may be a contact or non-contact encoder.The encoder 27002 shown in FIGS. 62-63 is for illustrative purposes andnot meant to limit the type of encoder. The encoder wheel 22202 mayinclude a non-slip surface or may include a tire with a non-slip tosurface to help ensure engagement with the inspection surface andincrease accuracy of the encoder measurements (no false readings due toslipping of the encoder wheel). The encoder limbs 22206, 22208 may bejoined by a flexible joint 22204 to enable the encoder wheel 22202 tomove vertically in response to an obstacle on the inspection surface.The encoder connector 22210 may be designed to break-away from thehousing in response to an obstacle on the inspection surface, anopposing force, and the like. Breaking away reduces the chance that theencoder 21718 can act like a lever to peel the inspection robot 21700off an inspection surface if a large obstacle was encountered.

In embodiments, the encoder 21718, 27002 may include a hall effectsensor and the movement value 27016 may be representative of changes inmagnetic flux. In embodiments, the encoder may include a visual mark onthe wheel, a visual sensor. The movement value 27016 may then bereflective of a stream of optical data, a wheel count, of the like.

The encoder 21718 may be active or passive. In embodiments, the encoderconnector 22210 may include a spring structured to provide a downwardforce on the encoder 21718 while still allowing a limited amount ofvertical freedom for traversing small obstacles or irregularities in theinspection surface. The encoder connector 22210 may include an actuatorto actively adjust a position, force, or angle of the encoder 21718relative to the inspection surface. The actuator may provide a downwardforce on the encoder 21718 to ensure good contact with the inspectionsurface, the actuator may raise the encoder 21718 up, such as to avoidan obstacle on the inspection surface, the actuator may move the encoder21718 to a storage position, and the like.

Referring to FIGS. 111-112, an inspection robot 27100, may include ahousing 26802, and at least one drive module 26804 operatively linked tothe house, where the drive module 26804 comprises at least one wheel26812 and a motor 26814. The inspection robot 27100 may also include afirst sled 27102 with a first sensor 27104 and a second sled 27108 witha second sensor 27110. The inspection robot 27100 may include a payload27112 made up of a first rail component 27114 with at least a firstconnector 27118 and a second rail component 27120 with at a secondconnector 27122. The connectors 27118, 27122 are each a portion of Hirthjoint, allowing the first and second rail components 27114, 27120 to beconnected at a discrete engagement position or angle where theengagement position or angle may be selected based on the geometry orcontours of the inspection surface. The first and second sleds 27102,27108 include quick release connectors shaped to easily attach to therail components 27114, 27120. In some embodiments there may be a lockingfeature such as a bolt, screw, pin or the like which may be designed topass through the center of the Hirth joint and hold the first and secondrail components 27114, 27120 together.

In embodiments the first and second rail components 27114, 27120 mayhave more than a single connector 27132. Rail components may be variablein length. In an illustrative example, the second rail component 27120may have a third connector 27124. There may be a third rail component27128 with a fourth connector 27130. The second rail component may bejoined to the first rail component 27114 and the third rail component.Thus, a payload may be made of a variable number of rail components ofvarying length with each connection between two rail components may beset to a unique, discrete engagement position or angle. The selection ofthe engagement positions may be based on features of the inspectionsurface.

Referring to FIGS. 65-68 shows examples 22500, 22600, 22700, 22800rails. FIGS. 65-66 show examples of rail components 22502 and connectors22504. The connectors shown are Hirth joints although others arecontemplated. FIG. 67 shows three rail components 22502 connectedlinearly to form a straight payload rail 22700. FIG. 68 shows three railcomponents 22502 connected at angle relative to each other to form acurved payload 22800.

Referring to FIG. 113, a flowchart for a method 27300 for provisioningan inspection robot is shown. The method 27300 includes attaching afirst rail component to a second rail component at selected one of aplurality of discrete engagement positions (Step 27302) and attachingthe second rail component to a third rail component at a second selectedone of a plurality of discrete engagement positions (Step 27304). Oncethe payload 27112 is assembled, attaching a first sensor sled to thefirst rail component (Step 27308) and attaching a second sensor sled toa second or third rail component (Step 27310) are done. The method 27300may then include verifying that the first and second selected discreteengagement positions enable contact between each sled and the inspectionsurface (Step 27312) and adjusting the discrete engagement positions(angles between rail components) as needed to enable contact (Step27314).

Referring to FIG. 114, an inspection robot 27400, may include a housing102 having a first connector 27402 on a first side of the housing 102and a second connector 27404 on a second side of the housing, a firstdrive module 26804A may include at least one wheel 26812A and a firstmotor 26814A and a second drive module 26804B may include at least onewheel 26812B and a second motor 26814B.

In some embodiments, a drive module 26804 may include the wheel 26812interposed between the housing 26802 and the motor 26814. A wheel 26812may be a steerable wheel designed to allow the inspection robot to bemaneuvered on the inspection surface. A wheel 26812 may be a drivenwheel where a motor 26814 causes the wheel 26812 to turn and propel theinspection robot 27400 over the inspection surface. In embodiments, awheel 26812 may be a steerable, driven wheel.

In embodiments, a motor 26814 may be directly coupled to a wheel 26812such as the motor being in line with the wheel such that the rotation ofthe motor 26814 rotates an axel or hub of the wheel 26812. Inembodiments, a wheel 26812 may be interposed between the housing 26802and a motor 26814. This may mean that the wheel 26812 is closer to thehousing 26802 than the motor 26814 when both wheel 26812 and motor 26814are outside a footprint of the housing. Note, the term footprint,footprint of the housing 26802, housing footprint, and similar suchterms refer to a projection of the housing 26802 onto the inspectionsurface and the corresponding space between the housing 26802 and theinspection surface including the projection. When either a wheel 26812,or a wheel 26812 and corresponding motor 26814 are partially or whollywithin the housing footprint, the wheel 26812 being interposed betweenthe motor 26814 and the housing 26802 means that it is closer to ahorizontal center of the housing 26802 relative to the motor 26814. Thispositioning of the wheel closer to the center of the inspection robot27400 may provide a smaller wheel footprint (i.e., a tighter wheelbase)which may improve the maneuverability of the inspection robot 27400 inconfined areas or when inspecting high curvature assets such as pipes.

In embodiments, a motor 26814 may be indirectly coupled to a wheel 26812and drives the wheel via gears, belts, and the like. A motor 26814 maybe positioned in front, above, or behind a wheel 26812 relative to adirection of travel (see FIGS. 59-61). Drive modules are swappable sothe relative position of a motor 26814 and wheel 26812 may vary betweendrive modules 26804 connected to a common housing 26802. In embodiments,motors 26814 may have a common position relative to a wheel 26812, e.g.,all motors 26814 may be positioned in front of their correspondingwheels 26812, all motors 26814 may be positioned behind theircorresponding wheels 26812, or all motors 26814A may be positioned ontop of their corresponding wheels 26812A. In embodiments, motors 26814may each have a unique position relative to their corresponding wheels26812 on a common inspection robot 27400, For example, on an inspectionrobot 27400, a motor 26814A may be in front of a wheel 26812A in a firstattached drive module 26804 and, for a second attached drive module26804, a motor 26814B may be positioned behind or above thecorresponding wheel(s) 26812B.

In embodiments, the location of wheels 26812 and motors 26814 relativeto the housing 26802 may be unique. For one drive module 26804, thewheel 26812 may be fully in the housing footprint while the motor 26814was positioned partially or fully outside the housing footprint. Foranother drive module 26804 attached to the housing 26802, both the wheel26812 and motor 26814 may be fully in the housing footprint or fullyoutside the footprint. The drive modules may be selected for therelative positions of the wheels 26812 and motors 26814 in order to bestaccommodate an inspection surface, for example to inspect as closely aspossible to a wall bordering one side of the inspection surface.

Referring to FIG. 115, an inspection robot 27500 may include a housing26802 having a first connector 27402 and a second connector 27404. Theconnectors 27402, 27404 may be located on the same side of the housingor on different or opposite sides of the housing 26802. A first drivemodule 26804A including a first wheel 26812A and a first motor 26814Amay be operatively coupled to the first connector 27402 and a seconddrive module 26804B, including a second wheel 26812B and a second motor26814B, may be operatively coupled to the second connector 27404. Adrive connector 27503 may couple the first and second drive modules26804A, 26804B. A drive connector 27503 may include a joint 27504 whichallows the first and second drive modules 26804A, 26804B to rotaterelative to one another (rotation 27506) around a first axis 27510 whichis at a first angle relative to the direction of travel 27508. The firstaxis 27510 may be perpendicular to the direction of travel 27508.Additional drive modules 26804 may also be connected to the housing26802 via an additional connector 27406.

With reference to FIG. 125, there is illustrated an example wheel 27200.It shall be appreciated that wheel 27200 may be incorporated into any ofthe drive modules, inspection robots, systems, assemblies, or otherembodiments described herein.

Wheel 27200 includes plurality of layers structured to form a wheel whenan axle is inserted through the plurality of layers. The plurality oflayers includes wheel enclosures 27201 and 27203, inter-covers 27205 and27207, diffusion barriers 27213 and 27215, and a magnetic hub 27209.

Wheel enclosure 27201 and 27203 are structured to contact an inspectionsurface 27217 while an inspection robot is positioned on inspectionsurface 27217. Wheel enclosures 27201 and 27203 may be non-ferrous andinclude non-ferrous material. The non-ferrous material may include ametallic material, such as aluminum, zinc, or bronze, to name but a fewexamples. The non-ferrous material may include a plastic, such as Viton,Poly Urethane (PU), or ethylene propylene diene terpolymer (EPDM), toname but a few examples. In certain embodiments, wheel enclosures 27201and 27203 may be any material having a hardness less than the hardnessof inspection surface 27217 in order to prevent marring. Because thenon-ferrous wheel enclosures are not magnetically coupled to magnetichub 27209, the wheel enclosures are more readily replaced due to wear,damage, or to accommodate the inspection surface material.

On the outer surface of each wheel enclosure 27201 and 27203, there is aserration texture 27211. In the illustrated embodiment, serrationtexture 27211 includes a plurality of horizontal serrations across awidth of each wheel enclosure. Serration texture 27211 may includetooth-like projections arranged lengthwise in parallel. The serrationsinclude a serration pitch which may be selected to increase tractionbetween the wheel enclosure and the inspection surface or to preventmarring of the inspection surface, to name but a few examples. For hightemperature inspection surfaces, a serration texture may be used insteadof tires fitted over a wheel enclosure given the higher temperaturethreshold of the wheel enclosure compared to the tires. For example, theserration texture may be used for inspection surface temperaturesgreater than 300 degrees Fahrenheit.

Inter-covers 27205 and 27207 are interposed between the wheel enclosures27201, 27203 and magnetic hub 27209 and may be structured to guide amagnetic field of magnetic hub 27209. For example, inter-covers 27205and 27207 may be structured to guide the magnetic field in order toprevent damage to electronic components of the inspection robot intowhich wheel 27200 is incorporated, or to increase the holding power ofmagnetic hub 27209 to inspection surface 27217. The magnetic field maybe guided by shaping the magnetic field lines produced by the magnet ofmagnetic hub 27209. Inter-covers 27205 and 27207 may include aferromagnetic material, such as carbon steel, to name but one example.In certain embodiments, a carbon steel plate of inter-covers 27205 and27207 is coated with an anti-corrosion coating, such as a zinc coating,to name but one example. In certain embodiments, wheel 27200 does notinclude one or both of inter-covers 27205 and 27207.

Magnetic hub 27209 is interposed between inter-covers 27205 and 27207.Hub 27209 includes a magnet structured to generate a magnetic field inorder to magnetically couple wheel 27200 to inspection surface 27217. Asthe environment of the inspection surface 27217 varies, the magneticfield of a given magnet may weaken to the extent the magnet produces amagnet field with insufficient holding power to magnetically couplewheel 27200 to inspection surface 27217. In certain embodiments,magnetic hub includes a high temperature magnet having a hightemperature threshold, such as a threshold greater than 300 degreesFahrenheit, to name but one example. The high temperature threshold maycorrespond to the temperature at which the intensity of the magneticfield begins to decrease due to temperature or at which the intensity ofthe magnetic field is insufficient to generate the holding power tomagnetically couple wheel 27200 to inspection surface 27217. The hightemperature magnet may be comprised of a rare earth metal. In certainembodiments, the high temperature magnet may be comprised of neodymium,samarium cobalt (SmCo), ceramic, or alnico (Al, Ni, Co), to name but afew examples.

Diffusion barriers 27213 and 27215 are structured to prevent damagecaused by two other dissimilar layers of wheel 27200 (e.g., distinctmetals) being in contact with each other. Diffusion barriers 27213 and27215 may include at least one of a coating, a surface hardening, or anon-metallic cover. In certain embodiments, diffusion barriers 27213 and27215 are incorporated into one of the wheel enclosures, theinter-covers, or the magnetic hub of wheel 27200.

Diffusion barriers 27213 and 27215 are interposed between magnetic hub27209 and one of the inter-covers 27205 and 27207. In certainembodiments where wheel 27200 does not include inter-covers 27205 and27207, diffusion barriers 27213 and 27215 are interposed betweenmagnetic hub 27209 and non-ferrous wheel enclosures 27201 and 27203. Incertain embodiments, wheel 27200 includes a diffusion barrier interposedbetween a wheel enclosure and an inter-cover. For example, wheel 27200may include a diffusion barrier between a non-ferrous wheel enclosure27201 and inter-cover 27205. In certain embodiments, wheel 27200 doesnot include inter-covers but includes a diffusion barrier betweenmagnetic hub 27209 and one, but not both, wheel enclosures 27201 and27203. In certain embodiments, wheel 27200 includes fewer diffusionbarriers or no diffusion barriers.

In certain embodiments, wheel 27200 may be formed by a user based oninspection surface characteristics and operating characteristics of aplurality of different wheel enclosures. The user may form wheel 27200using a kit including the plurality of different wheel enclosures whichinclude different characteristics, such as different hardnesses ordifferent temperature thresholds. The kit may also include a pluralityof magnets with different temperature thresholds and differentinter-covers. For example, for a high temperature inspection surface,the user may select aluminum wheel enclosures with serration texture onthe outer surfaces, carbon steel plate inter-covers, and a hightemperature magnet.

With reference to FIG. 126, there is illustrated an example process28800 for inspecting an inspection surface. Process 28800 may beimplemented in whole or in part in one or more of the inspection robotsdisclosed herein. It shall be further appreciated that variations of andmodifications to process 28800 are contemplated including, for example,the omission of one or more aspects of process 28800, the addition offurther conditionals and operations, or the reorganization or separationof operations and conditionals into separate processes.

Process 28800 begins at operation 28801 including determining at leastone inspection surface characteristic. The inspection surfacecharacteristic may include a temperature of the inspection surfaceand/or a hardness of the inspection surface, to name but a few examples.

Process 28800 proceeds to operation 28803 including selecting a firstwheel enclosure having a serration texture from a plurality of wheelenclosures in response to the at least one inspection surfacecharacteristic.

Process 28800 proceeds to operation 28805 including selecting a secondwheel enclosure having the serration texture from the plurality of wheelenclosures in response to the at least one inspection surfacecharacteristic.

In certain embodiments, selecting the one or more wheel enclosuresincludes determining the hardness of the at least one inspection surfacecharacteristic is greater than a hardness of the non-ferrous material.By selecting a wheel enclosure with a hardness less than a hardness ofthe inspection surface, the wheel enclosure is structured to contact theinspection surface without marring the inspection surface.

In certain embodiments, determining the temperature of the at least oneinspection surface characteristic is less than a temperature thresholdof the first wheel enclosure. In this way, the selected wheel enclosuresare structured to withstand the temperature of the inspection surfacewithout being damaged.

Process 28800 proceeds to operation 28807 including assembling a wheelof an inspection robot, the wheel including an axle inserted through thefirst wheel enclosure, a magnetic hub, and a second wheel enclosure. Incertain embodiments, the wheel enclosures each comprise a non-ferrousmaterial so as not to be magnetically coupled to the magnetic in orderto more easily swap wheel enclosures, assemble the wheel, anddisassemble the wheel.

Process 28800 proceeds to operation 28809 including moving theinspection robot on an inspection surface such that the first wheelenclosure and the second wheel enclosure each directly contact theinspection surface.

It shall be appreciated that any or all of the foregoing features ofexample process 28800 may also be present in the other processesdisclosed herein, such as the process illustrated in FIG. 127, to namebut one example.

With reference to FIG. 127 there is illustrated an example inspectionprocess 28900 for inspecting an inspection surface. Process 28900 may beimplemented in whole or in part in one or more of the inspection robotsdisclosed herein. It shall be further appreciated that variations of andmodifications to process 28900 are contemplated including, for example,the omission of one or more aspects of process 28900, the addition offurther conditionals and operations, or the reorganization or separationof operations and conditionals into separate processes.

Process 28900 begins at operation 28901 including operating aninspection robot including a wheel including a magnetic hub including amagnet having a first temperature threshold and a plurality of wheelenclosures having a second temperature threshold. The components of thewheel may have different temperature thresholds due to being composed ofdifferent materials. The temperature threshold for the magnetic hub maybe based on the temperature at which a magnetic field of the magnetichub begins to reduce or is reduced to a level insufficient tomagnetically couple the wheel to the inspection surface during aninspection.

Process 28900 proceeds to operation 28903 including determining aninspection surface temperature exceeds at least one of the firsttemperature threshold or the second temperature threshold. For example,the wheel enclosure may include tires that are damaged by an inspectionsurface temperature above 300 degrees Fahrenheit, to name but oneexample.

Process 28900 proceeds to operation 28905 including reconfiguring thewheel in response to determining the inspection surface temperatureexceeds the at least one of the first temperature threshold or thesecond temperature threshold. Where the inspection surface temperatureexceeds the temperature threshold for the wheel enclosures but not thetemperature threshold for the magnetic hub, reconfiguring the wheelincludes replacing the wheel enclosures with other wheel enclosureshaving a third temperature threshold greater than the inspection surfacetemperature. In certain embodiments, reconfiguring the wheel includesselecting the second plurality of wheel enclosures based on the thirdtemperature threshold and a hardness of the new wheel enclosuresrelative to an inspection surface hardness. Where the inspection surfacetemperature exceeds the temperature threshold for the magnetic hub,reconfiguring the wheel includes replacing the first magnet with a hightemperature magnet having a temperature threshold greater than theinspection surface temperature. To give but one example, the temperaturethreshold for the high temperature magnet or the replacement wheelenclosures may be equal to or greater than 300 degrees Fahrenheit.

It shall be appreciated that any or all of the foregoing features ofexample process 28800 may also be present in the other processesdisclosed herein, such as the process illustrated in FIG. 127, to namebut one example.

With reference to FIGS. 128A and 128B, there is illustrated an exampleinspection robot 28700 structured to move across an inspection surfacewhile the wheels of the inspection robot maintain contact with theinspection surface. In certain embodiments, the inspection surfacecomprises a pipe, a plurality of pipes, or another type of unevensurface. In certain embodiments, the inspection robot must perform tightturns while inspecting the inspection surface.

Inspection robot 28700 includes a center body 28701 and a suspensionsystem 28703 coupled to center body 28701. A plurality of drive modules28710, including drive module 28712, are coupled to suspension system28703. Each of the plurality of drive modules 28710 includes a wheel anda motor, such as wheel 28711 and motor 28713 of drive module 28712. Thewheel of each drive module is positioned between center body 28701 andthe motor of the drive module such that center body 28701 is located ona first side of the side and the corresponding motor is positioned onthe opposite side of the wheel.

Suspension system 28703 is structured to allow each of the plurality ofdrive modules 28710 to rotate independently of the rotation of the otherdrive modules. In certain embodiments, suspension system 28703 isstructured to allow a vertical rotation 28715 of each drive moduleindependent of the other drive modules. In certain embodiments,suspension system 28703 is structured to allow a horizontal rotation28717 of each drive module independent of the other drive modules.

By allowing independent rotation of each of the plurality of drivemodules 28710, each wheel of the inspection robot maintains contact withthe inspection robot while the inspection robot traverses uneveninspection surfaces. By positioning the motors on the outside of thedrive modules and the wheels on the inside, inspection robot 28700 isstructured to negotiate a tighter turn compared to an inspection robotwith drive modules having a wheel position on the outside of the drivemodule.

It shall be appreciated that any or all of the foregoing features ofinspection robot 28700 may also be present in the other inspectionrobots disclosed herein.

With reference to FIG. 129, there is illustrated an example inspectionrobot 27600. Robot 27600 includes a center body 27601 coupled to asuspension system 27603. Inspection robot 27600 also includes aplurality of drive modules, such as drive module 27610, structured to becoupled to suspension system 27603 at a plurality of connection points,such as connection point 27602. In certain embodiments, each drivemodule of the plurality of drive modules is swappable with another drivemodule of inspection robot 27600.

Each drive module of inspection robot 27600 is structured to receivepower from center body 27601, communicate with center body 27601, andreceive cooling fluid from center body 27601. Center body 27601 includesseparate power, communication, and cooling fluid interfaces for eachdrive module. For example, center body 27601 includes power interface27609, communication interface 27607, and cooling fluid interface 27605corresponding to drive module 27610. In the illustrated embodiment,center body 27601 includes a distinct interface plate, such as interfaceplate 27604, for each drive module connection point. In otherembodiments, center body 27601 may include a different arrangement ofinterface plates, such as an interface plate for multiple drive modules,an interface plate for one type of interface for multiple modules, or aninterface plate for two types of interfaces for multiple modules. Incertain embodiments, the interface plate or plates of center body 27601are removeable and may be replaced based on the number of drive modulescoupled to center body 27601. In certain embodiments, one or more of theinterfaces of center body 27601 are not coupled to removeable interfaceplates.

Each drive module includes interfaces structured to be coupled to thecorresponding interfaces of center body 27601. For example, drive module27610 includes a power interface 27611, a communication interface 27613,and a cooling fluid interface 27615. Center body 27601 may be configuredto operate the interfaces corresponding to each drive moduleindependently from the operation of the other drive modules. Forexample, center body 27601 may transmit a power value to drive module27610 by way of power interface 27609 while transmitting a differentpower value to another drive module of inspection robot 27600. Inanother example, center body 27601 may transmit a command to drivemodule 27610 while transmitting a different command or no command toanother drive module of inspection robot 27600. In still anotherexample, center body 27601 may transmit cooling fluid to drive module27610 by way of cooling fluid interface 27605 at a rate whiletransmitting cooling fluid at a different rate to another drive module.

In the illustrated embodiment of FIG. 128A, inspection robot 28700includes four drive modules. In certain embodiments, additional drivemodules may be coupled to the unused connection points of suspensionsystem 27603. For example, inspection robot 27600 may be reconfigured toinclude six drive modules. In other embodiments, inspection robot 27600may include three drive modules instead of four drive modules.

It shall be appreciated that any or all of the foregoing features ofinspection robot 27600 may also be present in the other inspectionrobots disclosed herein.

With reference to FIG. 116, there is illustrated an example process27700 for assembling an inspection robot. Process 27700 may beimplemented in whole or in part in one or more of the inspection robotsor robot controllers disclosed herein. It shall be further appreciatedthat variations of and modifications to process 27700 are contemplatedincluding, for example, the omission of one or more aspects of process27700, the addition of further conditionals and operations, or thereorganization or separation of operations and conditionals intoseparate processes.

Process 27700 begins at operation 27701 including coupling a pluralityof drive modules to a center body of the inspection robot by way of aplurality of power interfaces of the center body.

Process 27700 proceeds to operation 27703 including coupling theplurality of drive modules to the center body by way of a plurality ofcommunication interfaces of the center body.

Process 27700 proceeds to operation 27705 including coupling theplurality of drive modules to the center body by way of a plurality ofcooling fluid interfaces of the center body.

It shall be appreciated that any or all of the foregoing features ofexample process 27700 may also be present in the other processesdisclosed herein, such as the processes illustrated in FIGS. 117-121, toname but a few examples.

With reference to FIG. 117, there is illustrated an example process27800 for assembling an inspection robot. Process 27800 may beimplemented in whole or in part in one or more of the inspection robotsor robot controllers disclosed herein. It shall be further appreciatedthat variations of and modifications to process 27800 are contemplatedincluding, for example, the omission of one or more aspects of process27800, the addition of further conditionals and operations, or thereorganization or separation of operations and conditionals intoseparate processes.

Process 27800 begins at operation 27801 including coupling a pluralityof drive modules to a center body of the inspection robot by way of aplurality of power interfaces of the center body.

Process 27800 proceeds to operation 27803 including coupling theplurality of drive modules to the center body by way of a plurality ofcommunication interfaces of the center body.

Process 27800 proceeds to operation 27805 including coupling theplurality of drive modules to the center body by way of a plurality ofcooling fluid interfaces of the center body.

Process 27800 proceeds to operation 27807 including decoupling a firstdrive module of the plurality of drive modules from the center bodywithout decoupling other drive modules of the plurality of drivemodules. By individually coupling each drive module to dedicated power,communication, and cooling fluid interfaces on the center body, a drivemodule may be removed without altering the coupling of other drivemodules.

It shall be appreciated that any or all of the foregoing features ofexample process 27800 may also be present in the other processesdisclosed herein, such as the processes illustrated in FIGS. 117 and117-121, to name but a few examples.

With reference to FIG. 118, there is illustrated an example process27900 for assembling an inspection robot. Process 27900 may beimplemented in whole or in part in one or more of the inspection robotsor robot controllers disclosed herein. It shall be further appreciatedthat variations of and modifications to process 27900 are contemplatedincluding, for example, the omission of one or more aspects of process27900, the addition of further conditionals and operations, or thereorganization or separation of operations and conditionals intoseparate processes.

Process 27900 begins at operation 27901 including coupling a pluralityof drive modules to a center body of the inspection robot by way of aplurality of power interfaces of the center body.

Process 27900 proceeds to operation 27903 including coupling theplurality of drive modules to the center body by way of a plurality ofcommunication interfaces of the center body; and

Process 27900 proceeds to operation 27905 including coupling theplurality of drive modules to the center body by way of a plurality ofcooling fluid interfaces of the center body.

Process 27900 proceeds to operation 27907 including decoupling a firstdrive module of the plurality of drive modules from the correspondingpower interface, communication interface, and cooling fluid interface.

Process 27900 proceeds to operation 27909 including decoupling a seconddrive module of the plurality of drive modules from the center body.

Process 27900 proceeds to operation 27911 including coupling the seconddrive module to the power interface, communication interface, andcooling fluid interface previously corresponding to the first drivemodule. The drive modules of the inspection robot may be swappable, inthat each drive module is structured to connect to any drive moduleconnection point of the inspection robot and to connect with theinterfaces corresponding to the connection point.

It shall be appreciated that any or all of the foregoing features ofexample process 27900 may also be present in the other processesdisclosed herein, such as the processes illustrated in FIGS. 117-118 and119-126, to name but a few examples.

With reference to FIG. 119, there is illustrated an example process28000 for assembling an inspection robot. Process 28000 may beimplemented in whole or in part in one or more of the inspection robotsor robot controllers disclosed herein. It shall be further appreciatedthat variations of and modifications to process 28000 are contemplatedincluding, for example, the omission of one or more aspects of process28000, the addition of further conditionals and operations, or thereorganization or separation of operations and conditionals intoseparate processes.

Process 28000 proceeds to operation 28001 including determining a numberof the plurality of drive modules to couple to the center body. Incertain embodiments, the number of drive modules coupled to the centerbody may be based on a required aggregate holding power to theinspection surface, or based on an aggregate motor power requirement, toname but a few examples.

Process 28000 proceeds to operation 28003 including selecting aninterface plate of the center body in response to determining the numberof the plurality of drive modules to couple to the center body. Theinterface plate may be selected such that the number of interfaces onthe interface plate is equal to or greater than the number of interfacesrequired for the determined number of drive modules.

Process 28000 proceeds to operation 28005 including coupling theselected interface plate to the center body.

Process 28000 proceeds to operation 28007 including coupling a pluralityof drive modules to a center body of the inspection robot by way of aplurality of power interfaces of the center body.

Process 28000 proceeds to operation 28009 including coupling theplurality of drive modules to the center body by way of a plurality ofcommunication interfaces of the center body; and

Process 28000 proceeds to operation 28011 including coupling theplurality of drive modules to the center body by way of a plurality ofcooling fluid interfaces of the center body.

It shall be appreciated that any or all of the foregoing features ofexample process 28000 may also be present in the other processesdisclosed herein, such as the processes illustrated in FIGS. 116-118 and120-121, to name but a few examples.

With reference to FIG. 120, there is illustrated an example process28100 for assembling an inspection robot. Process 28100 may beimplemented in whole or in part in one or more of the inspection robotsor robot controllers disclosed herein. It shall be further appreciatedthat variations of and modifications to process 28100 are contemplatedincluding, for example, the omission of one or more aspects of process28100, the addition of further conditionals and operations, or thereorganization or separation of operations and conditionals intoseparate processes.

Process 28100 begins at operation 28101 including coupling a pluralityof drive modules to a center body of the inspection robot by way of aplurality of power interfaces of the center body.

Process 28100 proceeds to operation 28103 including coupling theplurality of drive modules to the center body by way of a plurality ofcommunication interfaces of the center body; and

Process 28100 proceeds to operation 28105 including coupling theplurality of drive modules to the center body by way of a plurality ofcooling fluid interfaces of the center body.

Process 28100 proceeds to operation 28107 including determining anaggregate power requirement of the plurality of drive modules. Incertain embodiments, the aggregate power requirement includes a torquerequirement or a horsepower requirement.

Process 28100 proceeds to operation 28109 including coupling anadditional drive module to the center body in response to determiningthe aggregate power requirement of the plurality of drive modules.

It shall be appreciated that any or all of the foregoing features ofexample process 28100 may also be present in the other processesdisclosed herein, such as the processes illustrated in FIGS. 116-119 and121, to name but a few examples.

With reference to FIG. 121, there is illustrated an example process28200 for assembling an inspection robot. Process 28200 may beimplemented in whole or in part in one or more of the inspection robotsor robot controllers disclosed herein. It shall be further appreciatedthat variations of and modifications to process 28200 are contemplatedincluding, for example, the omission of one or more aspects of process28500, the addition of further conditionals and operations, or thereorganization or separation of operations and conditionals intoseparate processes.

Process 28200 begins at operation 28201 including coupling a pluralityof drive modules to a center body of the inspection robot by way of aplurality of power interfaces of the center body.

Process 28200 proceeds to operation 28203 including coupling theplurality of drive modules to the center body by way of a plurality ofcommunication interfaces of the center body; and

Process 28200 proceeds to operation 28205 including coupling theplurality of drive modules to the center body by way of a plurality ofcooling fluid interfaces of the center body.

Process 28200 proceeds to operation 28207 including determining anaggregate holding power of the plurality of drive modules to aninspection surface.

Process 28200 proceeds to operation 28209 including coupling anadditional drive module to the center body in response to determiningthe aggregate holding power of the plurality of drive modules. Forexample, the aggregate holding power may be insufficient to magneticallycouple the inspection robot to an inspection surface, and an additionaldrive module is added to the inspection robot in order to increase theaggregate holding power.

It shall be appreciated that any or all of the foregoing features ofexample process 28200 may also be present in the other processesdisclosed herein, such as the processes illustrated in FIGS.116-120-124, to name but a few examples.

With reference to FIG. 130, there is a box diagram illustrating anexample inspection robot 28300. Robot 28300 includes a center body 28301and a plurality of drive modules coupled to center body 28301, such asdrive module 28310. Each drive module includes a sensing circuit and avisual indicator circuit, such as sensing circuit 28311 and visualindicator circuit 28313 of drive module 28310.

Sensing circuit 28311 is structured to measure a drive module operatingcharacteristic of drive module 28310. In certain embodiments, sensingcircuit 28311 includes a temperature sensing device. The drive moduleoperating characteristic may include a power electronics temperature, acooling fluid temperature, or an ambient temperature. In certainembodiments, the drive module operating characteristic may include avoltage, a current, a vibration, or a humidity, to name but a fewexamples. In certain embodiments, sensing circuit 28311 includes acurrent sensing device structured to measure an electric current of thedrive module, such as a motor drive current, to name but one example.

Visual indicator circuit 28313 is structured to output a visualindicator corresponding to the drive module operating characteristic.Visual indicator circuit 28313 may coordinate with the other visualindicator circuit so as to simultaneously output visual indicatorscorresponding to the same type of drive module operating characteristic.The visual indicator circuits of the plurality of drive modules arepositioned to be simultaneously visible at a point of view. The point ofview may be the point of view of a user or the point of view of sensingdevice, such as a camera or light sensor, to name but a few examples.

In certain embodiments, the visual indicator for each drive module isbased on a gradient of the drive module operating characteristic. Incertain embodiments, the visual indicator corresponds to a temperatureor a temperature gradient of drive module 28310. In certain embodiments,the visual indicator corresponds to a current of drive module 28310.

In certain embodiments, visual indicator circuit 28313 includes a lightsource structured to output the visual indicator. The light source mayinclude a light bulb, a light emitting diode, or a graphic display, toname but a few examples.

In the illustrated embodiment, center body 28301 also includes a sensingcircuit and a visual indicator circuit structured to output a visualindicator based on a robot operating characteristic.

It shall be appreciated that any or all of the foregoing features ofcircuits 28311 and 28313 may also be present in the other sensingcircuit and visual indicator circuits of inspection robot 28300.

In certain embodiments, a camera of an inspection robot controller islocated at the point of view, and inspection robot 28300 is structuredto receive a command from the inspection robot controller in response tothe visual indicators for the plurality of drive modules.

It shall be appreciated that any or all of the foregoing features ofinspection robot 28300 may also be present in the other inspectionrobots disclosed herein.

With reference to FIG. 122, there is illustrated an example process28400 for visualizing inspection robot statuses. Process 28400 7 may beimplemented in whole or in part in one or more of the inspection robotsdisclosed herein. It shall be further appreciated that variations of andmodifications to process 28400 are contemplated including, for example,the omission of one or more aspects of process 28400, the addition offurther conditionals and operations, or the reorganization or separationof operations and conditionals into separate processes.

Process 28400 begins at operation 28401 including sensing a plurality ofdrive module operating characteristics, each of the plurality of drivemodule operating characteristics corresponding to a drive module of aplurality of drive modules of an inspection robot. In certainembodiments, the plurality of drive module operating characteristicsincludes an electric current or a temperature for each of the pluralityof drive modules.

Process 28400 proceeds to operation 28403 including determining a drivemodule status for each drive module of the plurality of drive modules inresponse to the plurality of drive module operating characteristics. Incertain embodiments, the drive module status for each drive module ofthe plurality of drive modules includes a direction of movement, atemperature gradient, a temperature, a current gradient, a currentmagnitude, a fault condition, or a predictive fault condition.

Process 28400 proceeds to operation 28405 including outputting a visualindicator from each drive module of the plurality of drive modules, thevisual indicator corresponding to the drive module status for thecorresponding drive module.

In certain embodiments, outputting the visual indicator from each drivemodule of the plurality of drive modules includes outputting the visualindicator for a first drive module corresponding to a predictive faultcondition of the first drive module.

In certain embodiments, outputting the visual indicator from each drivemodule of the plurality of drive modules includes simultaneouslyoutputting the visual indicator from each drive module of the pluralityof drive modules. In certain embodiments, the visual indicator from eachdrive module of the plurality of drive modules corresponds to a currentgradient or a temperature gradient of the corresponding drive module.

It shall be appreciated that any or all of the foregoing features ofexample process 28400 may also be present in the other processesdisclosed herein, such as the processes illustrated in FIGS. 123-124, toname but a few examples.

With reference to FIG. 123, there is illustrated an example process28500 for visualizing inspection robot statuses. Process 28500 may beimplemented in whole or in part in one or more of the inspection robotsdisclosed herein. It shall be further appreciated that variations of andmodifications to process 28500 are contemplated including, for example,the omission of one or more aspects of process 28500, the addition offurther conditionals and operations, or the reorganization or separationof operations and conditionals into separate processes.

Process 28500 begins at operation 28501 including sensing a plurality ofdrive module operating characteristics, each of the plurality of drivemodule operating characteristics corresponding to a drive module of aplurality of drive modules of an inspection robot.

Process 28500 proceeds to operation 28503 including determining a drivemodule status for each drive module of the plurality of drive modules inresponse to the plurality of drive module operating characteristics.

Process 28500 proceeds to operation 28505 including outputting a visualindicator from each drive module of the plurality of drive modules, thevisual indicator corresponding to the drive module status for thecorresponding drive module.

Process 28500 proceeds to operation 28507 including adjusting aninspection robot operation in response to the outputting the visualindicator from each drive module of the plurality of drive modules. Incertain embodiments, adjusting the inspection robot operation includesadjusting a coolant flow rate, adjusting a motor speed of at least oneof the plurality of drive modules, or adjusting a direction of movementfor at least one of the plurality of drive modules.

It shall be appreciated that any or all of the foregoing features ofexample process 28500 may also be present in the other processesdisclosed herein, such as the processes illustrated in FIGS. 121 and124, to name but a few examples.

With reference to FIG. 124, there is illustrated an example process28600 for visualizing inspection robot statuses. Process 28600 may beimplemented in whole or in part in one or more of the inspection robotsdisclosed herein. It shall be further appreciated that variations of andmodifications to process 28600 are contemplated including, for example,the omission of one or more aspects of process 28600, the addition offurther conditionals and operations, or the reorganization or separationof operations and conditionals into separate processes.

Process 28600 begins at operation 28601 including sensing a plurality ofdrive module operating characteristics, each of the plurality of drivemodule operating characteristics corresponding to a drive module of aplurality of drive modules of an inspection robot.

Process 28600 proceeds to operation 28603 including determining a drivemodule status for each drive module of the plurality of drive modules inresponse to the plurality of drive module operating characteristics.

Process 28600 proceeds to operation 28605 including outputting a visualindicator from each drive module of the plurality of drive modules, thevisual indicator corresponding to the drive module status for thecorresponding drive module.

Process 28600 proceeds to operation 28607 including receiving the visualindicator from each drive module of the plurality of drive modules.

Process 28600 proceeds to operation 28609 including transmitting anotification in response to receiving the visual indicator from eachdrive module of the plurality of drive modules.

It shall be appreciated that any or all of the foregoing features ofexample process 28600 may also be present in the other processesdisclosed herein, such as the processes illustrated in FIGS. 122-124, toname but a few examples.

Any one or more of the terms computer, computing device, processor,circuit, controller, and/or server include a computer of any type,capable to access instructions stored in communication thereto such asupon a non-transient computer readable medium, whereupon the computerperforms operations of systems or methods described herein uponexecuting the instructions. In certain embodiments, such instructionsthemselves comprise a computer, computing device, processor, circuit,controller, and/or server. Additionally or alternatively, a computer,computing device, processor, circuit, controller, and/or server may be aseparate hardware device, one or more computing resources distributedacross hardware devices, and/or may include such aspects as logicalcircuits, embedded circuits, sensors, actuators, input and/or outputdevices, network and/or communication resources, memory resources of anytype, processing resources of any type, and/or hardware devicesconfigured to be responsive to determined conditions to functionallyexecute one or more operations of systems and methods herein.

Elements of the present disclosure are described in a particulararrangement and context for clarity of the present description. Forexample, controllers and/or circuits are depicted as a single componentpositioned within a given system. However, any components may bedistributed in whole or part, for example a circuit positioned on morethan one controller, electronic board, or the like. In certainembodiments, the distributed elements cooperate to perform selectedoperations of the circuit and/or controller, and accordingly the circuitand/or controller is embodied in the group of distributed elements forsuch embodiments. In certain embodiments, for example based uponspecific operating conditions, the presence of a fault and/or componentfailure, alternative elements may be utilized to perform one or moreoperations of the circuit and/or controller (e.g., using a drive motormonitor of a drive module where an encoder is not present, and/or wherethe encoder is not operational), and accordingly the circuit and/orcontroller may be further embodied in the alternative elements, and/orembodied in primary elements at a first time, and embodied (at least inpart) in alternative elements at a second time.

Certain operations described herein include interpreting, receiving,and/or determining one or more values, parameters, inputs, data, orother information. Operations including interpreting, receiving, and/ordetermining any value parameter, input, data, and/or other informationinclude, without limitation: receiving data via a user input; receivingdata over a network of any type; reading a data value from a memorylocation in communication with the receiving device; utilizing a defaultvalue as a received data value; estimating, calculating, or deriving adata value based on other information available to the receiving device;and/or updating any of these in response to a later received data value.In certain embodiments, a data value may be received by a firstoperation, and later updated by a second operation, as part of thereceiving a data value. For example, when communications are down,intermittent, or interrupted, a first operation to interpret, receive,and/or determine a data value may be performed, and when communicationsare restored an updated operation to interpret, receive, and/ordetermine the data value may be performed.

Certain logical groupings of operations herein, for example methods orprocedures of the current disclosure, are provided to illustrate aspectsof the present disclosure. Operations described herein are schematicallydescribed and/or depicted, and operations may be combined, divided,re-ordered, added, or removed in a manner consistent with the disclosureherein. It is understood that the context of an operational descriptionmay require an ordering for one or more operations, and/or an order forone or more operations may be explicitly disclosed, but the order ofoperations should be understood broadly, where any equivalent groupingof operations to provide an equivalent outcome of operations isspecifically contemplated herein. For example, if a value is used in oneoperational step, the determining of the value may be required beforethat operational step in certain contexts (e.g., where the time delay ofdata for an operation to achieve a certain effect is important), but maynot be required before that operation step in other contexts (e.g.,where usage of the value from a previous execution cycle of theoperations would be sufficient for those purposes). Accordingly, incertain embodiments an order of operations and grouping of operations asdescribed is explicitly contemplated herein, and in certain embodimentsre-ordering, subdivision, and/or different grouping of operations isexplicitly contemplated herein.

Numerous embodiments described throughout the present disclosure arewell suited to successfully execute inspections of inspection surfaceshaving flat and/or varying curvature geometries. For example, payloadarrangements described herein allow for freedom of movement of sensorsleds to maintain operational contact with the inspection surface overthe entire inspection surface space. Additionally, control of theinspection robot movement with positional interaction, includingtracking inspection surface positions that have been inspected,determining the position of the inspection robot using dead reckoning,encoders, and/or absolute position detection, allows for assurance thatthe entire inspection surface is inspected according to a plan, and thatprogression across the surface can be performed without excessiverepetition of movement. Additionally, the ability of the inspectionrobot to determine which positions have been inspected, to utilizetransformed conceptualizations of the inspection surface, and theability of the inspection robot to reconfigure (e.g., payloadarrangements, physical sensor arrangements, down force applied, and/orto raise payloads), enable and/or disable sensors and/or datacollection, allows for assurance that the entire inspection surface isinspected without excessive data collection and/or utilization ofcouplant. Additionally, the ability of the inspection robot to traversebetween distinct surface orientations, for example by lifting thepayloads and/or utilizing a stability support device, allows theinspection robot to traverse distinct surfaces, such as surfaces withina tank interior, surfaces in a pipe bend, or the like. Additionally,embodiments set forth herein allow for an inspection robot to traverse apipe or tank interior or exterior in a helical path, allowing for aninspection having a selected inspection resolution of the inspectionsurface within a single pass (e.g., where representative points areinspected, and/or wherein the helical path is selected such that thehorizontal width of the sensors overlaps and/or is acceptably adjacenton subsequent spirals of the helical path).

It can be seen that various embodiments herein provide for an inspectionrobot capable to inspect a surface such as an interior of a pipe and/oran interior of a tank. Additionally, embodiments of an inspection robotherein are operable at elevated temperatures relative to acceptabletemperatures for personnel, and operable in composition environments(e.g., presence of CO₂, low oxygen, etc.) that are not acceptable topersonnel. Additionally, in certain embodiments, entrance of aninspection robot into certain spaces may be a trivial operation, whereentrance of a person into the space may require exposure to risk, and/orrequire extensive preparation and verification (e.g., lock-out/tag-outprocedures, confined space procedures, exposure to height procedures,etc.). Accordingly, embodiments throughout the present disclosureprovide for improved cost, safety, capability, and/or completion time ofinspections relative to previously known systems or procedures.

The methods and systems described herein may be deployed in part or inwhole through a machine having a computer, computing device, processor,circuit, and/or server that executes computer readable instructions,program codes, instructions, and/or includes hardware configured tofunctionally execute one or more operations of the methods and systemsdisclosed herein. The terms computer, computing device, processor,circuit, and/or server, as utilized herein, should be understoodbroadly.

Any one or more of the terms computer, computing device, processor,circuit, and/or server include a computer of any type, capable to accessinstructions stored in communication thereto such as upon anon-transient computer readable medium, whereupon the computer performsoperations of systems or methods described herein upon executing theinstructions. In certain embodiments, such instructions themselvescomprise a computer, computing device, processor, circuit, and/orserver. Additionally or alternatively, a computer, computing device,processor, circuit, and/or server may be a separate hardware device, oneor more computing resources distributed across hardware devices, and/ormay include such aspects as logical circuits, embedded circuits,sensors, actuators, input and/or output devices, network and/orcommunication resources, memory resources of any type, processingresources of any type, and/or hardware devices configured to beresponsive to determined conditions to functionally execute one or moreoperations of systems and methods herein.

Network and/or communication resources include, without limitation,local area network, wide area network, wireless, internet, or any otherknown communication resources and protocols. Example and non-limitinghardware, computers, computing devices, processors, circuits, and/orservers include, without limitation, a general purpose computer, aserver, an embedded computer, a mobile device, a virtual machine, and/oran emulated version of one or more of these. Example and non-limitinghardware, computers, computing devices, processors, circuits, and/orservers may be physical, logical, or virtual. A computer, computingdevice, processor, circuit, and/or server may be: a distributed resourceincluded as an aspect of several devices; and/or included as aninteroperable set of resources to perform described functions of thecomputer, computing device, processor, circuit, and/or server, such thatthe distributed resources function together to perform the operations ofthe computer, computing device, processor, circuit, and/or server. Incertain embodiments, each computer, computing device, processor,circuit, and/or server may be on separate hardware, and/or one or morehardware devices may include aspects of more than one computer,computing device, processor, circuit, and/or server, for example asseparately executable instructions stored on the hardware device, and/oras logically partitioned aspects of a set of executable instructions,with some aspects of the hardware device comprising a part of a firstcomputer, computing device, processor, circuit, and/or server, and someaspects of the hardware device comprising a part of a second computer,computing device, processor, circuit, and/or server.

A computer, computing device, processor, circuit, and/or server may bepart of a server, client, network infrastructure, mobile computingplatform, stationary computing platform, or other computing platform. Aprocessor may be any kind of computational or processing device capableof executing program instructions, codes, binary instructions and thelike. The processor may be or include a signal processor, digitalprocessor, embedded processor, microprocessor or any variant such as aco-processor (math co-processor, graphic co-processor, communicationco-processor and the like) and the like that may directly or indirectlyfacilitate execution of program code or program instructions storedthereon. In addition, the processor may enable execution of multipleprograms, threads, and codes. The threads may be executed simultaneouslyto enhance the performance of the processor and to facilitatesimultaneous operations of the application. By way of implementation,methods, program codes, program instructions and the like describedherein may be implemented in one or more threads. The thread may spawnother threads that may have assigned priorities associated with them;the processor may execute these threads based on priority or any otherorder based on instructions provided in the program code. The processormay include memory that stores methods, codes, instructions and programsas described herein and elsewhere. The processor may access a storagemedium through an interface that may store methods, codes, andinstructions as described herein and elsewhere. The storage mediumassociated with the processor for storing methods, programs, codes,program instructions or other type of instructions capable of beingexecuted by the computing or processing device may include but may notbe limited to one or more of a CD-ROM, DVD, memory, hard disk, flashdrive, RAM, ROM, cache and the like.

A processor may include one or more cores that may enhance speed andperformance of a multiprocessor. In embodiments, the process may be adual core processor, quad core processors, other chip-levelmultiprocessor and the like that combine two or more independent cores(called a die).

The methods and systems described herein may be deployed in part or inwhole through a machine that executes computer readable instructions ona server, client, firewall, gateway, hub, router, or other such computerand/or networking hardware. The computer readable instructions may beassociated with a server that may include a file server, print server,domain server, internet server, intranet server and other variants suchas secondary server, host server, distributed server and the like. Theserver may include one or more of memories, processors, computerreadable transitory and/or non-transitory media, storage media, ports(physical and virtual), communication devices, and interfaces capable ofaccessing other servers, clients, machines, and devices through a wiredor a wireless medium, and the like. The methods, programs, or codes asdescribed herein and elsewhere may be executed by the server. Inaddition, other devices required for execution of methods as describedin this application may be considered as a part of the infrastructureassociated with the server.

The server may provide an interface to other devices including, withoutlimitation, clients, other servers, printers, database servers, printservers, file servers, communication servers, distributed servers, andthe like. Additionally, this coupling and/or connection may facilitateremote execution of instructions across the network. The networking ofsome or all of these devices may facilitate parallel processing ofprogram code, instructions, and/or programs at one or more locationswithout deviating from the scope of the disclosure. In addition, all thedevices attached to the server through an interface may include at leastone storage medium capable of storing methods, program code,instructions, and/or programs. A central repository may provide programinstructions to be executed on different devices. In thisimplementation, the remote repository may act as a storage medium formethods, program code, instructions, and/or programs.

The methods, program code, instructions, and/or programs may beassociated with a client that may include a file client, print client,domain client, internet client, intranet client and other variants suchas secondary client, host client, distributed client and the like. Theclient may include one or more of memories, processors, computerreadable transitory and/or non-transitory media, storage media, ports(physical and virtual), communication devices, and interfaces capable ofaccessing other clients, servers, machines, and devices through a wiredor a wireless medium, and the like. The methods, program code,instructions, and/or programs as described herein and elsewhere may beexecuted by the client. In addition, other devices utilized forexecution of methods as described in this application may be consideredas a part of the infrastructure associated with the client.

The client may provide an interface to other devices including, withoutlimitation, servers, other clients, printers, database servers, printservers, file servers, communication servers, distributed servers, andthe like. Additionally, this coupling and/or connection may facilitateremote execution of methods, program code, instructions, and/or programsacross the network. The networking of some or all of these devices mayfacilitate parallel processing of methods, program code, instructions,and/or programs at one or more locations without deviating from thescope of the disclosure. In addition, all the devices attached to theclient through an interface may include at least one storage mediumcapable of storing methods, program code, instructions, and/or programs.A central repository may provide program instructions to be executed ondifferent devices. In this implementation, the remote repository may actas a storage medium for methods, program code, instructions, and/orprograms.

The methods and systems described herein may be deployed in part or inwhole through network infrastructures. The network infrastructure mayinclude elements such as computing devices, servers, routers, hubs,firewalls, clients, personal computers, communication devices, routingdevices and other active and passive devices, modules, and/or componentsas known in the art. The computing and/or non-computing device(s)associated with the network infrastructure may include, apart from othercomponents, a storage medium such as flash memory, buffer, stack, RAM,ROM and the like. The methods, program code, instructions, and/orprograms described herein and elsewhere may be executed by one or moreof the network infrastructural elements.

The methods, program code, instructions, and/or programs describedherein and elsewhere may be implemented on a cellular network havingmultiple cells. The cellular network may either be frequency divisionmultiple access (FDMA) network or code division multiple access (CDMA)network. The cellular network may include mobile devices, cell sites,base stations, repeaters, antennas, towers, and the like.

The methods, program code, instructions, and/or programs describedherein and elsewhere may be implemented on or through mobile devices.The mobile devices may include navigation devices, cell phones, mobilephones, mobile personal digital assistants, laptops, palmtops, netbooks,pagers, electronic books readers, music players, and the like. Thesemobile devices may include, apart from other components, a storagemedium such as a flash memory, buffer, RAM, ROM and one or morecomputing devices. The computing devices associated with mobile devicesmay be enabled to execute methods, program code, instructions, and/orprograms stored thereon. Alternatively, the mobile devices may beconfigured to execute instructions in collaboration with other devices.The mobile devices may communicate with base stations interfaced withservers and configured to execute methods, program code, instructions,and/or programs. The mobile devices may communicate on a peer to peernetwork, mesh network, or other communications network. The methods,program code, instructions, and/or programs may be stored on the storagemedium associated with the server and executed by a computing deviceembedded within the server. The base station may include a computingdevice and a storage medium. The storage device may store methods,program code, instructions, and/or programs executed by the computingdevices associated with the base station.

The methods, program code, instructions, and/or programs may be storedand/or accessed on machine readable transitory and/or non-transitorymedia that may include: computer components, devices, and recordingmedia that retain digital data used for computing for some interval oftime; semiconductor storage known as random access memory (RAM); massstorage typically for more permanent storage, such as optical discs,forms of magnetic storage like hard disks, tapes, drums, cards and othertypes; processor registers, cache memory, volatile memory, non-volatilememory; optical storage such as CD, DVD; removable media such as flashmemory (e.g., USB sticks or keys), floppy disks, magnetic tape, papertape, punch cards, standalone RAM disks, Zip drives, removable massstorage, off-line, and the like; other computer memory such as dynamicmemory, static memory, read/write storage, mutable storage, read only,random access, sequential access, location addressable, fileaddressable, content addressable, network attached storage, storage areanetwork, bar codes, magnetic ink, and the like.

Certain operations described herein include interpreting, receiving,and/or determining one or more values, parameters, inputs, data, orother information. Operations including interpreting, receiving, and/ordetermining any value parameter, input, data, and/or other informationinclude, without limitation: receiving data via a user input; receivingdata over a network of any type; reading a data value from a memorylocation in communication with the receiving device; utilizing a defaultvalue as a received data value; estimating, calculating, or deriving adata value based on other information available to the receiving device;and/or updating any of these in response to a later received data value.In certain embodiments, a data value may be received by a firstoperation, and later updated by a second operation, as part of thereceiving a data value. For example, when communications are down,intermittent, or interrupted, a first operation to interpret, receive,and/or determine a data value may be performed, and when communicationsare restored an updated operation to interpret, receive, and/ordetermine the data value may be performed.

Certain logical groupings of operations herein, for example methods orprocedures of the current disclosure, are provided to illustrate aspectsof the present disclosure. Operations described herein are schematicallydescribed and/or depicted, and operations may be combined, divided,re-ordered, added, or removed in a manner consistent with the disclosureherein. It is understood that the context of an operational descriptionmay require an ordering for one or more operations, and/or an order forone or more operations may be explicitly disclosed, but the order ofoperations should be understood broadly, where any equivalent groupingof operations to provide an equivalent outcome of operations isspecifically contemplated herein. For example, if a value is used in oneoperational step, the determining of the value may be required beforethat operational step in certain contexts (e.g. where the time delay ofdata for an operation to achieve a certain effect is important), but maynot be required before that operation step in other contexts (e.g. whereusage of the value from a previous execution cycle of the operationswould be sufficient for those purposes). Accordingly, in certainembodiments an order of operations and grouping of operations asdescribed is explicitly contemplated herein, and in certain embodimentsre-ordering, subdivision, and/or different grouping of operations isexplicitly contemplated herein.

The methods and systems described herein may transform physical and/oror intangible items from one state to another. The methods and systemsdescribed herein may also transform data representing physical and/orintangible items from one state to another.

The elements described and depicted herein, including in flow charts,block diagrams, and/or operational descriptions, depict and/or describespecific example arrangements of elements for purposes of illustration.However, the depicted and/or described elements, the functions thereof,and/or arrangements of these, may be implemented on machines, such asthrough computer executable transitory and/or non-transitory mediahaving a processor capable of executing program instructions storedthereon, and/or as logical circuits or hardware arrangements. Examplearrangements of programming instructions include at least: monolithicstructure of instructions; standalone modules of instructions forelements or portions thereof; and/or as modules of instructions thatemploy external routines, code, services, and so forth; and/or anycombination of these, and all such implementations are contemplated tobe within the scope of embodiments of the present disclosure Examples ofsuch machines include, without limitation, personal digital assistants,laptops, personal computers, mobile phones, other handheld computingdevices, medical equipment, wired or wireless communication devices,transducers, chips, calculators, satellites, tablet PCs, electronicbooks, gadgets, electronic devices, devices having artificialintelligence, computing devices, networking equipment, servers, routersand the like. Furthermore, the elements described and/or depictedherein, and/or any other logical components, may be implemented on amachine capable of executing program instructions. Thus, while theforegoing flow charts, block diagrams, and/or operational descriptionsset forth functional aspects of the disclosed systems, any arrangementof program instructions implementing these functional aspects arecontemplated herein. Similarly, it will be appreciated that the varioussteps identified and described above may be varied, and that the orderof steps may be adapted to particular applications of the techniquesdisclosed herein. Additionally, any steps or operations may be dividedand/or combined in any manner providing similar functionality to thedescribed operations. All such variations and modifications arecontemplated in the present disclosure. The methods and/or processesdescribed above, and steps thereof, may be implemented in hardware,program code, instructions, and/or programs or any combination ofhardware and methods, program code, instructions, and/or programssuitable for a particular application. Example hardware includes adedicated computing device or specific computing device, a particularaspect or component of a specific computing device, and/or anarrangement of hardware components and/or logical circuits to performone or more of the operations of a method and/or system. The processesmay be implemented in one or more microprocessors, microcontrollers,embedded microcontrollers, programmable digital signal processors orother programmable device, along with internal and/or external memory.The processes may also, or instead, be embodied in an applicationspecific integrated circuit, a programmable gate array, programmablearray logic, or any other device or combination of devices that may beconfigured to process electronic signals. It will further be appreciatedthat one or more of the processes may be realized as a computerexecutable code capable of being executed on a machine readable medium.

The computer executable code may be created using a structuredprogramming language such as C, an object oriented programming languagesuch as C++, or any other high-level or low-level programming language(including assembly languages, hardware description languages, anddatabase programming languages and technologies) that may be stored,compiled or interpreted to run on one of the above devices, as well asheterogeneous combinations of processors, processor architectures, orcombinations of different hardware and computer readable instructions,or any other machine capable of executing program instructions.

Thus, in one aspect, each method described above, and combinationsthereof may be embodied in computer executable code that, when executingon one or more computing devices, performs the steps thereof. In anotheraspect, the methods may be embodied in systems that perform the stepsthereof, and may be distributed across devices in a number of ways, orall of the functionality may be integrated into a dedicated, standalonedevice or other hardware. In another aspect, the means for performingthe steps associated with the processes described above may include anyof the hardware and/or computer readable instructions described above.All such permutations and combinations are contemplated in embodimentsof the present disclosure.

1. An inspection robot, comprising: a payload mounted to a housing ofthe inspection robot, the payload comprising at least one sensor mountedthereon; the housing comprising a removeable interface plate, theremoveable interface plate coupled to the at least one sensor on a firstside, and coupled to an electronic board on a second side, wherein theelectronic board is positioned within the housing; and the removeableinterface plate defining an electrical coupling interface compatiblewith the payload, wherein the electronic board comprises an electricalprocessing configuration compatible with the payload.
 2. The inspectionrobot of claim 1, wherein the electronic board further comprises anelectrical communication configuration compatible with the payload. 3.The inspection robot of claim 1, wherein the electrical couplinginterface comprises at least one characteristic selected from a list ofcharacteristics consisting of: a number of connections; a voltagerating; a current rating; a connector type value; and an I/O pinconfiguration.
 4. The inspection robot of claim 1, wherein theremoveable interface plate further defines a couplant connection fluidlycoupled to the payload on the first side and to a couplant source on thesecond side.
 5. The inspection robot of claim 1, wherein the electronicboard comprises a dedicated board having a payload specificconfiguration, and wherein the electronic board is releasably mounted toa main board positioned within the housing.
 6. The inspection robot ofclaim 5, wherein the payload specific configuration comprises at leastone configuration value selected from a list of values consisting of: aselected A/D processing configuration; a selected communicationdefinition; a selected pre-processing definition; a selected payloadidentification definition; and a selected payload diagnostic definition.7. The inspection robot of claim 6, wherein the electronic board furthercomprises: a payload interface circuit structured to interpret signalsfrom the payload in response to the payload specific configuration; anda data distribution circuit structured to communicate data valuesrepresentative of data collected from the at least one sensor to anexternal device in response to the interpreted signals from the payload.8. The inspection robot of claim 7, wherein the data distributioncircuit is structured to communicate the data values representative ofdata collected from the at least one sensor to the external devicefurther in response to the payload specific configuration.
 9. Theinspection robot of claim 7, wherein the external device comprises atleast one device selected from the devices consisting of: a tethercoupled to the housing; a computing device communicatively coupled tothe inspection robot; a data acquisition circuit positioned within thehousing; a data acquisition circuit communicatively coupled to theinspection robot; and the main board.
 10. The inspection robot of claim7, wherein the electronic board further comprises: a payload statuscircuit structured to provide a payload identification value in responseto the payload specific configuration and further in response to thesignals from the payload.
 11. The inspection robot of claim 10, whereinthe payload identification value comprises at least one value selectedfrom a list of values consisting of: a unique payload identifier; apayload calibration value; and a payload type value.
 12. The inspectionrobot of claim 11, wherein the payload identification value furthercomprises a component identification value corresponding to at least onecomponent of the payload.
 13. The inspection robot of claim 12, whereinthe at least one component of the payload comprises a sled.
 14. Theinspection robot of claim 13, wherein the at least one componentcomprises the at least one sensor.
 15. The inspection robot of claim 14,wherein the component identification value comprises at least one of: aunique sensor identifier; a sensor calibration value; or a sensor typevalue.
 16. The inspection robot of claim 1, wherein the removeableinterface plate comprises a high temperature plastic.
 17. The inspectionrobot of claim 1, further comprising a quick connect coupling theremoveable interface plate to the housing.
 18. An inspection robot,comprising: a housing defining an interface opening, the housingcomprising a mount; a first payload comprising at least one first sensormounted thereon, the first payload configured to selectively couple tothe mount; a second payload comprising at least one second sensormounted thereon, the second payload configured to selectively couple tothe mount; a first removeable interface plate configured to mount to thehousing over the interface opening, the first removeable interface platehaving a first I/O interface compatible with the first payload on afirst side, and a first electrical interface on a second side; and asecond removeable interface plate configured to mount to the housingover the interface opening, the second removeable interface plate havinga second I/O interface compatible with the second payload on the firstside, and a second electrical interface compatible on the second side.19. The inspection robot of claim 18, further comprising an electronicboard positioned within the housing, wherein the electronic board iscompatible with both of the first electrical interface and the secondelectrical interface.
 20. The inspection robot of claim 19, wherein theelectronic board comprises a custom data acquisition circuit structuredto process data acquired by the selected payload.
 21. The inspectionrobot of claim 20, wherein the custom data acquisition circuit comprisesa custom configuration based, in part on: a geographic location, anenvironmental condition, a customer request, or a feature of aninspection surface.
 22. The inspection robot of claim 19, wherein theelectronic board comprises a payload interface circuit structured tointerpret signals from the first payload in response to a first payloadspecific configuration, and to interpret signals from the second payloadin response to a second payload specific configuration.
 23. Theinspection robot of claim 22, wherein the payload interface circuit isfurther structured to determine which one of the first payload or thesecond payload is mounted to the housing, and to select one of the firstpayload specific configuration or the second payload specificconfiguration in response to which one of the payloads is mounted to thehousing.
 24. The inspection robot of claim 23, wherein one of the firstpayload specific configuration or the second payload specificconfiguration is based, at least in part on, a geographic location, anenvironmental condition, a customer request, or a feature of aninspection surface.
 25. The inspection robot of claim 18, furthercomprising: a first electronic board compatible with the firstelectrical interface and configured to mount within the housing; and asecond electronic board compatible with the second electrical interfaceand configured to mount within the housing.
 26. The inspection robot ofclaim 25, wherein each of the first electronic board and the secondelectronic board are configured to mount on a payload support locationof a main board within the housing.
 27. A method, comprising: swapping afirst payload of an inspection robot to a second payload of theinspection robot, the first payload comprising a first sensor package,the second payload comprising a second sensor package, wherein the firstsensor package is distinct from the second sensor package; swapping afirst removeable interface plate mounted on a housing of the inspectionrobot over an interface opening to a second removeable interface platemounted on the housing of the inspection robot over the interfaceopening, wherein the first removeable interface plate comprises firstI/O interface compatible with the first payload, and wherein the secondremoveable interface plate comprises a second I/O interface compatiblewith the second payload; and operating the inspection robot tointerrogate at least a portion of an inspection surface with the secondpayload.
 28. The method of claim 27, further comprising updating a firstpayload specific configuration of a payload interface circuit to asecond payload specific configuration, wherein the first payloadspecific configuration comprises a first electrical interfacedescription for the first payload, and wherein the second payloadspecific configuration comprises a second electrical interfacedescription for the second payload.
 29. The method of claim 27, furthercomprising swapping a first electronic board compatible with a firstelectrical interface of the first payload to a second electronic boardcompatible with a second electrical interface of the second payload.30-340. (canceled)